TOHATSU MFS25 Service Manual
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TOHATSU MFS25 Service Manual

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OB No.003-21054-1
06-02 NB-2600

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Summary of Contents for TOHATSU MFS25

  • Page 1 Stroke OB No.003-21054-1 06-02 NB-2600...
  • Page 3 Introduction Before reading this manual This service manual provides information that is needed for inspection, service and repair of applicable outboard motors. For information about operation of the products that is not described in this document, refer to the operating instructions included in them at the delivery. For our customers' safe and comfortable use of the products for long time, it is essential to maintain the performance and quality of the outboards.

  • Page 4: Service Information

    Description of Pictogram The following symbols represent the contents of individual chapters. Service Fuel System Service Data Maintenance Information (Fuel Injection) Electrical Power Unit Lower Unit Bracket System Wiring r/min Troubleshooting Accessories Diagrams The following symbols indicate items needed for the service. Lubrication Tightening Special Tool...

  • Page 5: Table Of Contents

    1.Service Information 8) Inspection of Water Pump……………… 3-8 9) Replacement of Gear Oil ……………… 3-10 1 Identification (Engine Serial Number) …… 1-2 10) Inspection of Gear Case (for leakage) … 3-11 2 Securing of work safety …………… 1-2 1) Fire Prevention ……………………………… 1-2 11) Inspection of Timing Belt ………………...
  • Page 6 5 Ignition System 14) Inspection of Rocker Arm and Rocker Arm Shaft … 5-37 ………………………… 4-20 15) Inspection of Cam Shaft ……………… 5-38 (1) Configuration of Ignition System… 4-20 (2) Ignition Control ……………………… 16) Inspection of Cylinder Head …………… 5-39 4-21 17) Inspection of Oil Pump …………………...
  • Page 7 19) Assembly of Cam Rod and Clutch Cam … 6-16 16) Removing PTT Unit/Gas Shock Absorber … 7-24 20) Removing Drive Shaft ……………………… 6-16 17) Removing PTT Motor …………………… 7-25 21) Disassembly of Drive Shaft ……………… 6-16 18) Removing PTT Pump and Valves ……… 7-25 22) Inspection of Drive Shaft……………………...
  • Page 8 2) Inspection of Starter Solenoid …………… 8-21 10.Accessories 3) Disassembly of Starter Motor……………… 8-21 1 Remote Control Components …… 10-2 1) Installation of Remote Control Cable (Engine Side) 4) Inspection of Starter Motor Pinion ………… 8-22 Remote Control Model………………………… 10-2 5) Inspection of Armature ……………………...
  • Page 9 INDEX Service Information Service Data Maintenance Fuel System (Fuel Injection) Power Unit Lower Unit Bracket Electrical System Troubleshooting r/min Accessories Wiring Diagrams 25/30 2006...
  • Page 10 viii 25/30 2006...
  • Page 11 Service Information 1 Identification (Engine Serial Number) 2) Gear Shift………………………………… 1-10 …… 1-2 3) Engine Oil ……………………………… 1-10 2 Securing of work safety …………… 1-2 4) Gear Oil ………………………………… 1-10 1) Fire Prevention ……………………………… 1-2 5) Fuel Line ………………………………… 1-11 2) Ventilation ……………………………………...

  • Page 12: Identification (Engine Serial Number)

    Service Information 1. Identification (Engine Serial Number) Engine serial number is stamped on the bottom cowl of outboard motor body. 1 Model Name 2 Model Type Tokyo, Made in Japan 2006 Model 3 Serial Number SERIAL No. XXXXXXXX 18. 4 kW RATED POWER FULL THROTTLE RANGE 5000...

  • Page 13: Tools

    5) Tools Use specified special tools to prevent damaging to parts and to perform work safely and surely. Be sure to follow installation procedures described in this manual and use tightening torque specified. 3AC728710 6) Recommendations on service Remove foreign substances and dirt from outboard motor body and individual parts by cleaning.

  • Page 14: Cautions In Disassembling And Assembling Components

    Service Information 7) Cautions in disassembling and assembling components Secure outboard motor to dedicated stand firmly. Take special care not to scratch painted surface or mating surfaces of cylinder and crankcase. Replace unreusable parts such as packings, gaskets, O rings, oil seals, spring pins or split pins with new ones after they were removed .

  • Page 15: Tools And Instruments

    3. Tools and Instruments 1) Test Propeller P/N. 3R0-64111-0 Outer diameter : 223mm With : 11.5mm Rotational speed at WOT Outboard motor model (Wide Open Throttle) (r/min) 25 B approximately 5,200 30 B approximately 5,700 2) Measuring instruments For the following measuring instruments, use commercially available ones. Circuit tester ( Resistance : 1Ω, 10Ω, 10 kΩ, AC voltage : 30 to 300V, DC voltage : 30V ) Vernier calipers...

  • Page 16: List Of Special Tool

    Service Information 3) List of Special Tool Spring Pin Tool A Spring Pin Tool B Bevel Gear B Nut Wrench Bevel Gear B Nut Socket P/N. 345-72227-0 P/N. 345-72228-0 P/N. 346-72231-0 P/N. 346-72232-0 Removing spring pin Installing spring pin Removing/installing Pinion Nut (B Gear Nut) 346-72761-0 345-72762-0 345-72763-0...
  • Page 17 Valve Spring Compressor Slide Hammer Kit Oil Filter Wrench Flywheel Holder P/N. 3AC-99075-0 P/N. 3AC-99080-0 P/N. 3AC-99090-0 P/N. 3AC-99200-0 Removing forward gear Removing/installing Removing/installing valve Removing/installing oil filter (A gear) bearing outer race spring flywheel nut Shimming Gauge Center Plate Driver Rod P/N.
  • Page 18 Service Information Bearing attachment Center Plate 2 Driver Rod 2 P/N. 3AC-99905-0 P/N. 3AD-99701-0 P/N. 3AD-99702-0 Used with center plate and Used with driver rod Attaching Used with driver rod and needle bearing attachment needle bearing attachment reverse gear (C gear) bearing Positioning pinion gear (B gear) needle bearing Oil Seal Attachment 2 Needle Bearing Attachment 2...
  • Page 19 Clamp Plier Pressure Gauge Ass'y P/N. 3T5-72864-0 P/N. 3T5-72880-0 Caulking clamp Measuring fuel pressure 25/30 2006...

  • Page 20: Pre-Delivery Inspection

    Service Information 4. Pre-delivery Inspection å ∫ 1) Steering Handle å Check installations for clattering and play. ∫ Adjust steering friction. ç ∂ ç Check throttle grip for movement. (full open/full close). ∂ Adjust throttle friction. 2) Gear Shift Check that gear shifts from neutral (N) to forward (F) and reverse (R) smoothly.

  • Page 21: Fuel Line

    5) Fuel Line Check that fuel tank contains sufficient amount of gasoline, fuel line is connected and is free of leak. CAUTION Since this is a four stroke engine model, do not use fuel mixed with engine oil. Use of fuel mixed with engine oil will cause engine trouble.

  • Page 22: Inspection Of Starting Switch And Stop Switch

    Service Information 9) Inspection of starting switch and å stop switch Press start switch 1 or turn main switch to START 2 to check that engine starts. Turn main switch to OFF 3 to check that engine stops. å Tiller Handle Model ∫...

  • Page 23: Cooling Water Check Port

    10) Cooling water check port Check that cooling water check port 1 discharges water during engine runs. 11) Idling After engine has warmed up, use tachometer to check idle speed is as specified. Idle Speed : 850±30 r/min Tachometer : P/N.

  • Page 24: Trim Tab

    Service Information 13) Trim Tab Adjustment of trim tab angle After installing outboard motor on the boat, use trim tab to 1342 1342 1342 achieve balance between port and starboard steering loads. Loosen trim tab bolt, adjust angle of trim tab _ as described below, and then tighten the bolt to specified torque.

  • Page 25: Test Run

    6. Test Run Start engine and check if gear shift can be made smoothly. After completing warm-up operation, check idling revolution speed. Idling Revolution Speed : 850±30 r/min Tachometer : 1 High Tension Cord P/N. 3AC-99010-0 Shift gear into forward (F) and run dead slow for approximately 10 minutes.
  • Page 26 Service Information 1-16 25/30 2006...

  • Page 27: Service Data

    Service Data 1 Outline Dimensions 4 Cooling Water System Diagram …………………… 2-2 … 2-6 5 Specifications 1) Engine Dimensions ………………………… 2-2 ………………………… 2-7 6 Maintenance Data 2) Transom Bolts ……………………………… 2-3 ………………… 2-10 2 Fuel Injection System 7 Tightening Torque Data …………………...

  • Page 28: Outline Dimensions

    Service Data 1.Outline Dimensions 1) Engine Dimensions 25B/30B Item Type Unit mm/in 487.5 19.193 mm/in 699.5 27.539 mm/in 33.35 mm/in 38.35 mm/in 404.5 15.925 mm/in 21.73 mm/in 26.73 mm/in 17.64 mm/in 26.50 mm/in 4.80 mm/in 23.86 mm/in 16.73 Mechanical mm/in 15.12 PTT ·...

  • Page 29: Transom Bolts

    2) Transom Bolts CENTER LINE Mechanical Tilt Model 231mm(9.09in) 115.5mm(4.55in) 115.5mm(4.55in) ø10.5mm(0.41in) 85.5mm(3.37in) 85.5mm(3.37in) 171mm(6.73in) PTT or Gas Assisted Model 327mm(12.88in) 163.5mm(6.44in) 163.5mm(6.44in) ø13.0mm(0.51in) ø13.0mm(0.51in) 125.5mm(4.94in) 125.5mm(4.94in) 251mm(9.88in) 25/30 2006...

  • Page 30: Fuel Injection System

    Service Data 2.Fuel Injection System 1) ECU Fuel Feed System ECU uses various sensors to precisely control injected fuel amount and ignition timing. Fuel Feed Pump Alternator (FFP) Exciter Coils Fuel Control Alternator Fuel Injector ECU Charge Coil Pulser Coils ISC (Idle Speed Idle Control) Valve...

  • Page 31: Engine Lubrication System Diagram

    3.Engine Lubrication System Diagram Rocker Shaft Oil Regulator Oil Filter Main Gallery Cylinder Wall 25/30 2006...

  • Page 32: Cooling Water System Diagram

    Service Data 4.Cooling Water System Diagram Thermostat Cylinder Head Cylinder Fuel Cooler Thermostat Cooling Water Check Port Cylinder Cylinder Head Engine Base Fuel Idle Port Cooler Drive Shaft Housing Cooling Water Pipe Cooling Water Cooling Water Check Pump Port Cooling Water Intake Cylinder Lower Section (Water Feed Passage...

  • Page 33: Specifications

    5.Specifications Outboard Model Item Unit Dimensions (approx.) Overall Length mm (in) 1,031 (40.59) 652 (25.67) 1,031 (40.59) 652 (25.67) 1031 (40.59) 652 (25.67) Overall Width mm (in) 391 (15.39) 367 (14.45) 391 (15.39) 367 (14.45) 391 (15.39) 367 (14.45) Overall Height mm (in) 1,187 (46.73) mm (in)
  • Page 34 Service Data Outboard Model Item Unit Fuel & Oil Type of Fuel Unleaded Gasoline (Research Octane Number 90 or over,Pump posted Octane Number 87 or over) Fuel Tank Capacity Fuel Priming System ECU (Electronic Control Unit) Fuel Pumping System Mechanical (Plunger) pump + Electric System Type 4 Stroke Engine (Motor) Oil Grade...
  • Page 35 Outboard Model Item Unit Warning System Over-revolution Controls engine speed to approximately 6,300 r/min or Protection less. Warning buzzer sounds, and warning lamp is lit. Engine Hydraulic Controls engine speed to approximately 2,800 r/min or Pressure Low less (Low Speed ESG). Warning buzzer sounds, and warning lamp is lit. Engine Cooling Water Controls engine speed to approximately 2,800 r/min or Temperature Abnormally High.

  • Page 36: Maintenance Data

    Service Data 6.Maintenance Data Part Name Item Standard Value Cylinder Head Build up of carbon in combustion chamber Distortion or damage on mating surface Corrosion on the mating surface Cooling water passage clogged Cylinder Deposition in water jacket Wear of bore : Use cylinder gauge to 61.00mm (2.4016in) measure inner diameter.
  • Page 37 Functional Limit Action To Be Taken Clean to remove. 0.1mm (0.004in) Correct. (Use water proof sand paper of #240 to 400 on the surface plate to level. Use #600 to finish.) Correct if possible, or replace. Clean to remove. Clean to remove. 61.06mm (2.4039in) Replace if over specified limit.
  • Page 38 Service Data Part Name Item Standard Value Intake Valve Valve Clearance 0.15±0.02mm (0.006±0.001in) Exhaust Valve 0.20±0.02mm (0.008±0.001in) Valve Stem Outer Diameter 5.48mm (0.2157in) 5.46mm (0.2150in) Valve Guide Inner Diameter 5.51mm (0.2169in) 5.51mm (0.2169in) Clearance between valve 0.008 to 0.040mm (0.00031 to 0.00157in) guide and valve stem 0.025 to 0.057mm (0.00098 to 0.00224in) Width of contact with...
  • Page 39 Functional Limit Action To Be Taken Adjust into specifid range. 5.46mm (0.2150in) Replace if less than specified limit. 5.44mm (0.2142in) 5.55mm (0.2185in) Replace if over specified limit. 5.57mm (0.2193in) 0.070mm (0.00276in) Replace if over specified limit. 0.100mm (0.00394in) 2.0mm (0.08in) Replace if over specified limit.
  • Page 40 Service Data Part Name Item Standard Value Magneto Ignition Timing (at 850 r/min) BTDC 5°±5° Spark Performance (at 500 r/min) 10mm (0.4in) or over (Use genuine spark tester.) Alternator Output (at 5,000 r/min) 12V-180W Alternator Resistance Exciter Coil Between White/Red and White/Black 11 to 16Ω Between White/Blue and White/Black 11 to 16Ω...
  • Page 41 Functional Limit Action To Be Taken 10mm (0.4in) Replace if less than specified value. Replace if out of specified range. Replace if out of specified range. Replace if out of specified range. Replace if out of specified range. Clean to remove carbon build up and dirt. Adjust with side electrode. 1.2mm (0.047in) Replace if electrodes are severely worn.
  • Page 42 Service Data Part Name Item Standard Value Thermostat Valve Operation Starting Temperature (Submerged) 60°C±1.5°C (140±3°F) Valve Full Open Temperature (Submerged) 75°C (167°F) Valve Full Open Lift (Submerged) 3.0mm (0.12in) or over Pump Impeller Wear, Crack Pump Case (Liner) Wear Guide Plate Wear Anode Gear Case Anode Consumption...
  • Page 43 Functional Limit Action To Be Taken Any opening under ambient temperature Replace if out of specified range. 75°C (167°F) because thermostat operation is delayed. Measure valve open lift after 5 minutes. 3.0mm (0.12in) Replace if less than specified limit. Wear, crack or damage on tips and upper and lower Replace pump case liner and guide plate as a set.

  • Page 44: Tightening Torque Data

    Service Data 7.Tightening Torque Data Wrench A Screw B x Pitch Tightening Torque Fastened Components Type of Fastener N·m lb·ft kg·m First Tightening Torque : Engine Cylinder Block - Cylinder Head M8 x 1.25 Bolt Final Tightening Torque : First Tightening Torque : M6 x 1.0 Bolt Final Tightening Torque :...
  • Page 45 Wrench A Screw Size B Tightening Torque Fastened Components Type of Fastener N·m lb·ft kg·m Tilt Cylinder End – – 15.5 Tilt Rod Joint – Reservoir Tank – – Bolt Reserve Cap – – – 0.15 Motor Flange – – Screw 0.25 Manual Valve...

  • Page 46: Sealant Application Locations

    Service Data 8.Sealant Application Locations Item Name Remarks Konishi Three Bond Part Name Loctite Bond 1342 1373B 1141 1141C G17 LIT OBM 4ST GEAR Cylinder (Liner) Inner Wall Piston Ring Grooves, Periphery, Skirt Piston Rings Periphery Piston Pin Periphery Connecting Rod Big and Small Ends Metal Bearing [Cylinder Block, Crank Case] Both Faces...
  • Page 47 Item Name Remarks Konishi Part Name Three Bond Loctite Bond 1342 1373B 1141 1141C G17 LIT OBM 4ST GEAR Filler Cap O-Ring Periphery Solenoid Switch Terminals Plug Cap Spark Plug Insertion Area High Tension Cable Starter Motor Terminals Apply thin coat to pinion. Recoil Starter (Case) Reel Installation Bolt, Thread Frinction Plate,...
  • Page 48 Service Data Item Name Remarks Konishi Part Name Three Bond Loctite Bond 1342 1373B 1141 1141C G17 LIT OBM 4ST GEAR Exhaust Plug [D-Shaft Housing] Seal Rubber [Engine Base & Apron] Bolt [Pump Case (Upper)] Thread Pump Case (Upper) Impeller Sliding Area Water Pipe Seal (Lower) Connection Drive Shaft [Housing Side]...

  • Page 49: Maintenance

    Maintenance 1 Special Tool 15) Inspection of Compression Pressure … 3-18 ……………………………… 3-2 2 Inspection Schedule 16) Inspection and Adjustment of Valve Clearance … 3-19 ………………… 3-3 3 Inspection Items ……………………… 3-4 17) Throttle Cable Adjustment of Throttle Link … 3-20 1) Inspection of Top Cowl ……………………...

  • Page 50: Special Tool

    Maintenance 1. Special Tool Spring Pin Tool B Tachometer Compression Gauge Spring Pin Tool A P/N. 345-72227-0 P/N. 345-72228-0 P/N. 3AC-99010-0 P/N. 3AC-99030-0 Measuring engine revolution Measuring compression Removing spring pin Installing spring pin speed pressure Torque Wrench Valve Clearance Driver Oil Filter Wrench Flywheel Holder P/N.

  • Page 51: Inspection Schedule

    2. Inspection Schedule Inspection Period Initial 20 50 hours Inspection Part Inspection Item Remarks hours or hours or or Every Initial 1 Every 6 3 months month months Inspection, Cleaning, Fuel Filter Replacement Replace every 200 hours or High Pressure Fuel Filter Replace cartridge.

  • Page 52: Inspection Of Top Cowl

    Maintenance 3. Inspection Items 1) Inspection of Top Cowl Push top cowl to check for looseness and state of closing. 2) Inspection of Fuel System Piping Check the fuel system piping for fuel leak, dirt, deterioration and damage, and replace or clear parts if necessary. 25/30 2006...

  • Page 53: Inspection Of Fuel Tank

    3) Inspection of Fuel Tank 2 of fuel tank 1 counterclockwise Remove fuel pick up elbow to remove the part, and clean the filter 3. Remove dirt and water from fuel tank 1 if any. 2 Fuel Pick Up Elbow 3 Filter 4) Inspection of Fuel Filter Check fuel filter 4 for dirt, build up of fuel slag, and fuel filter...

  • Page 54: Replacement Of Engine Oil

    Maintenance 5) Replacement of Engine Oil Oil Level Oil Level Gauge Quantity of Oil for Full Replacement When oil filter When oil filter is replaced is not replaced Upper Limit 1.8L 1.6L Lower Limit 1.5L 1.3L Oil Specification Recommended Engine Oil : 4 Stroke Engine Oil API : SE, SF, SG, SH, SJ, SL 10W –...

  • Page 55: Replacement Of Oil Filter

    6) Replacement of Oil Filter Drain engine oil. Place a piece of rag below oil filter area, and remove it by using oil filter wrench 1. • Replace oil filter 5 minutes or more after stopping engine. • Wipe off spilt oil completely. Oil Filter Wrench 1 : P/N.

  • Page 56: Inspection Of Gear Oil Quantity

    Maintenance 7) Inspection of Gear Oil Quantity Tilt down outboard motor to make it vertical. Remove upper oil plug 1 and check level of gear oil in the gear case. Spill of some oil from plug hole as plug is removed indicates that gear case is filled with specified quantity of gear oil.
  • Page 57 Remove lower unit installation bolts, and pull lower unit ass'y downward to remove. Remove pump upper case 3. Remove impeller 4 and check it. Check upper pump case for deformation. Replace if necessary. Check impeller 4 and pump case liner 5 for crack and wear.

  • Page 58: Replacement Of Gear Oil

    Maintenance 9) Replacement of Gear Oil Tilt outboard motor a little as shown. Place drain oil pan below drain bolt 1, remove lower oil plug 1 and then upper oil plug 2 to drain oil. Remove lower oil plug first when draining. Check gear oil for presence of metal particles, change of color (abnormal if clouded), and viscosity.

  • Page 59: Inspection Of Gear Case (For Leakage)

    10) Inspection of Gear Case (for leakage) Drain gear oil. Remove upper oil plug 1 and connect a commercially available leakage tester to this hole. Apply specified pressure to gear base, and check if the pressure is maintained without further compression for 10 seconds.

  • Page 60: Inspection Of Timing Belt

    Maintenance 11) Inspection of Timing Belt Remove upper starter lock cable, and then recoil starter and belt cover. Check timing belt inner and outer surfaces for cracks, damages and wear while rotating flywheel clockwise with hands. Replace if necessary. " mark a of cam Rotate flywheel clockwise to bring "...

  • Page 61: Replacement Of Timing Belt

    12) Replacement of Timing Belt Disconnect upper starter lock cable. Remove recoil starter, belt cover and starter pulley. " mark a of cam Rotate flywheel 1 clockwise to bring " shaft pulley 2 to " " mark b of cylinder head. No.1 piston is to be at top dead center of compression stroke.
  • Page 62 Maintenance Remove flywheel and then key å CAUTION To prevent damages to engine and special tools, tighten flywheel puller set bolts evenly and keep flywheel puller parallel to flywheel while working. Screw puller onto crankshaft end until flywheel is disengaged from tapered section of crankshaft.

  • Page 63: Installation Of Timing Belt

    13) Installation of Timing Belt Align locating lines a of new timing belt 1 as shown, face part number size up, and engage belt with timing pulley 2 and then with cam shaft pulley 3. CAUTION • Be careful not give damage to timing belt when installing.
  • Page 64 Maintenance Turn timing pulley 2 approximately 25 degrees counterclockwise to move belt tensioner 4 until cam shaft pulley 3 shifts one tooth (approximately 11 degrees). The above step prevents excessive tensioning 11° of belt tensioner and allows fixing of the component to a properly adjusted position.

  • Page 65: Inspection Of Spark Plugs

    14) Inspection of Spark Plugs Remove plug cap and then spark plugs. Use spark plug cleaner or wire brush to clean spark plug electrodes 1 . Replace if necessary. Check electrodes 1 for corrosion or excessive build up of carbon, and washer 2 for damage. Replace if necessary. Check spark plug gap a.

  • Page 66: Inspection Of Compression Pressure

    Maintenance 15) Inspection of Compression Pressure Start and run engine for 5 minutes to warm up, and then stop. Shift gear into neutral (N). Remove lock plate (stop switch lanyard) from stop switch. CAUTION Remove lock plate (stop switch lanyard) from stop switch before measuring compression pressure.

  • Page 67: Inspection And Adjustment Of Valve Clearance

    16) Inspection and Adjustment of Valve Clearance ○ • Perform inspection and adjustment of valve clearances when engine is cold. • No.1 piston is to be at top dead center of compression stroke. ▲Marka Disconnect starter lock cables, and then recoil starter, belt cover, spark plugs, and cylinder head cover.

  • Page 68: Throttle Cable Adjustment Of Throttle Link

    Maintenance 17) Throttle Cable Adjustment of Throttle Link Set remote control lever to forward (F) WOT position. Or, set throttle grip to WOT position. Remove throttle link rod 3 from throttle drum 1 and throttle cam 2. Check length a of throttle link rod. If necessary, loosen lock nut 4 and adjust length.
  • Page 69 Attach throttle cable q. (Tiller Handle Model) • Put throttle cable q on the throttle drum 1 and attach it to throttle cable bracket 8. • Adjust position of lock nut w of throttle cable q so that throttle grip can reach full open and full close positions. Adjust cable tension so that it moves approximately 1mm when pushed lightly with a finger.
  • Page 70 Maintenance Adjust screw-in length of cable joint y so that hole of cable joint is brought to shift arm pin u. WARNING Screw-in remote control cable joint at lease 10mm i. After adjusting remote control cable joint, fix it with remote control cable fully pushed in. Lock joint with nut i, put it on the pin, and secure with washer and snap pin o.

  • Page 71: Inspection Of Shift Lever Gear Operations

    Reconnect cord ass'y connectors. CAUTION Do not disconnect cord ass'y while engine operates. Run cord ass'y a and remote control cables s through grommet p located on the front of bottom cowl. Attach remote control cable groove to bracket, and then fix it to bottom cowl.
  • Page 72 Maintenance Loosen lock nut 8, remove snap pin 9 and washer, and then remote control cable joint 7. (Remote Control Model) Adjust length so that remote control cable joint 7 hole aligns with set pin. (Remote Control Model) WARNING Screw-in remote control cable joint at lease 10mm b.

  • Page 73: Inspection Of Ptt Unit Operation

    19) Inspection of PTT Unit Operation Tilt up and down outboard motor several times to check that PTT unit operates smoothly in full range. Check PTT fluid quantity if necessary. Refer to "Inspection of PTT Fluid Quantity" described in the next page. Check that PTT motor produces noise of normal revolution.

  • Page 74: Inspection Of Ptt Fluid Quantity

    Maintenance 21) Inspection of PTT Fluid Quantity Fully tilt up outboard motor and lock with tilt stopper 1. WARNING Be sure to lock outboard motor with tilt stopper after fully tilting up. Leaving outboard motor without locking may lead to accidental descent due to reduction of PTT hydraulic pressure.

  • Page 75: Inspection Of Idle Speed

    22) Inspection of Idle Speed Start engine and run for 5 minutes to warm up. Attach tachometer to high tension cord 1 to check idle speed. More accurate and stable reading can be obtained when tachometer lead is connected with high tension cords of individual cylinders linked with each other.

  • Page 76: Inspection Of Anodes

    Maintenance 24) Inspection of Anodes Check anode 1 and trim tab 2 for build up of scale and adherence of grease and oil. Clean, or replace if necessary. å PTT/Gas Assist Model ∫ Mechanical Tilt Model CAUTION Do not coat anode and trim tab with oil, grease or paint, or their anti-corrosion function does not work normally.

  • Page 77: Inspection Of Propeller

    26) Inspection of Propeller Check propeller blades and spline for cracks, damages, wear and corrosion. Replace if necessary. 27) Inspection of Thermostat Remove fuel cooler. Remove cover 1 and thermostat 2. Hang thermostat 2 in the water contained in vessel. Put thermometer in the water, and warm up water to measure valve opening temperature.

  • Page 78: Inspection Of Cooling Water Passage

    Maintenance 28) Inspection of Cooling Water Passage Check water strainer 1 and sub water strainer 2 for clogging. Clean if necessary. Set outboard motor in the water and start engine. Check that cooling water is discharged from cooling water check port 3. If not, check water pump and cooling water passage in the engine.

  • Page 79: Flushing With Water

    29) Flushing with Water CAUTION Touching rotating propeller could lead to injury. Be sure to remove propeller before running engine on the land. WARNING Exhaust gas contains carbon monoxide, which will cause gas poisoning. Do not start engine with outboard motor placed in a closed area such as boat house.
  • Page 80 Maintenance Check that cooling water check port discharges water, and run engine for 3 to 5 minutes at low speed. Stop engine and stop water supply, remove flushing attachment 4, remove tape, attach and tighten water plug 5, and then, install propeller. Remove tape after flushing with water.

  • Page 81: Inspection Of Battery

    30) Inspection of Battery Inspect electrolyte level. If lower than "LOW" mark a, add distilled water until the level goes in between "UP" and "LOW" marks. Measure specific gravity of electrolyte. Charge battery if specific gravity is less than specified value. WARNING Electrolyte contains sulfuric acid that is poisonous and highly corrosive, which is...

  • Page 82: Greasing Points

    Maintenance 31) Greasing Points Apply grease to throttle cable and sliding areas. Put grease through grease nipples 1 until excessive grease appears from bush a. Apply grease to throttle cable and sliding areas. d Do not lubricate here. Apply thin coat of grease to starter motor pinion. Apply grease to terminals of starter motor, starter solenoid and PTT solenoid.

  • Page 83: Ecu System

    Fuel System (Fuel Injection) 1 Special Tools 5 Ignition System ……………………………… 4-2 ……………………… 4-20 2 Piping Arrangement Diagram (1) Configuration of Ignition System … …… 4-3 4-20 Fuel Hose, Vent Hose, Breather Hose, Cooling Water Hose … 4-3 (2) Ignition Control…………………… 4-21 3 Parts Layout ………………………………...

  • Page 84: Special Tools

    Fuel System (Fuel Injection) 1. Special Tools Vacuum/Pressure Gauge Clamp Plier Pressure Gauge Ass'y P/N. 3AC-99020-0 P/N. 3T5-72864-0 P/N. 3T5-72880-0 Inspecting pressure Caulking clamp Measuring fuel pressure 25/30 2006...

  • Page 85: Piping Arrangement Diagram

    2. Piping Arrangement Diagram Fuel Hose, Vent Hose, Breather Hose, Cooling Water Hose Rear Section Port Side Starboard Side Ref. Description No.. Fuel Hose (Fuel Connector to Fuel Filter) Fuel Hose (Fuel Filter to Fuel Pump) Fuel Hose (Fuel Pump to Vapor Separator) High Pressure Fuel Hose (Vapor Separator to Fuel Cooler) High Pressure Fuel Hose (Fuel Cooler to High Pressure Filter) High Pressure Fuel Hose (High Pressure Filter to T Nipple)

  • Page 86: Parts Layout

    Fuel System (Fuel Injection) 3. Parts Layout P/L Fig. 5 Fuel Pump, Fuel Rail, Vapor Separator 23-4 23-6 23-3 4st OIL 23-2 23-5 23-1 6 N·m (4 lb·ft) [0.6 kgf·m] 4st OIL 4st OIL 28-1 28-2 6 N·m (4 lb·ft) [0.6 kgf·m] Air Vent R/Mount To Fuel Pump...

  • Page 87: Fuel Pump, Fuel Rail, Vapor Separator

    P/L Fig. 5 Fuel Pump, Fuel Rail, Vapor Separator 23-4 23-6 23-3 4st OIL 23-2 23-5 23-1 6 N·m (4 lb·ft) [0.6 kgf·m] 4st OIL 4st OIL 28-1 28-2 6 N·m (4 lb·ft) [0.6 kgf·m] Air Vent R/Mount To Fuel Pump Bottom Cowl Cylinder Block To Fuel Rail...
  • Page 88 Fuel System (Fuel Injection) Fuel Pump, Fuel Rail, Vapor Separator P/L Fig. 5 10-16 10-13 10-15 10-14 4st OIL 4st OIL 10-11 10-2 4st OIL 10-18 10-10 10-6 10-4 10-7 17-3 10-3 10-12 10-5 10-12-1 17-1 10-1 4st OIL 4st OIL 17-1 17-2 17-2...

  • Page 89: Intake Manifold

    P/L Fig. 4 Intake Manifold 9 Nám (7 lbáft) [0.9 kgfám] 6 Nám (4 lbáft) [0.6 kgfám] 4st OIL 4st OIL 4st OIL Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Intake Manifold 20 Bolt 2 M6 L=12mm 1-1 Bolt, 5-10 21 Intake Silencer Ass'y 1 for ISC Valve 1-2 Washer, 5.3-12-1...

  • Page 90: Magneto & Ecu

    Fuel System (Fuel Injection) Magneto & ECU P/L Fig. 8 150 N·m (108 lb·ft) [15.0 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] 1342 1342 Fig.2 6 N·m (4 lb·ft) [0.6 kgf·m] 13-1 16-1 1342 1342 22 20 27-1 1342 1342 1342 Ref.

  • Page 91: Electric Parts

    P/L Fig. 9 Electric Parts 22 Nám (16 lbáft) [2.2 kgfám] 31-1 13 Nám (9 lbáft) [1.3 kgfám] 53-1 8 Nám (6 lbáft) [0.8 kgfám] 1342 1342 1342 1741 1741 1741 13 Nám (9 lbáft) [1.3 kgfám] o Intake Manifold o Intake Silencer 1342 1342...

  • Page 92: Intake Manifold

    Fuel System (Fuel Injection) P/L Fig. 9 Electric Parts 22 Nám (16 lbáft) [2.2 kgfám] 31-1 13 Nám (9 lbáft) [1.3 kgfám] 53-1 8 Nám (6 lbáft) [0.8 kgfám] 1342 1342 1342 1741 1741 1741 13 Nám (9 lbáft) [1.3 kgfám] o Intake Manifold o Intake Silencer 1342...
  • Page 93 P/L Fig. 24 Separate Fuel Tank Ref. Description Remarks Q'ty Fuel Tank ((25L, Plastic) 1-1 Fuel Gauge Vented Cap 1-2 Tank Cap Gasket 1-3 Male Quick Connector 1-4 Fuel Pick Up Elbow 1-5 O Ring Do not reuse. 1-6 Filter Primer Valve Ass'y 2-1 Rubber Hose 2-2 Fuel Connector (Tank Side, Female) 1...

  • Page 94: Ecu System

    Fuel System (Fuel Injection) 4. ECU System (1) Configuration of ECU System ECU uses various sensors to precisely control injected fuel amount and ignition timing. Fuel Regulator Controls fuel feed pump (FFP). Drives injectors. Drives ignition coils. Fuel Feed Pump Regulator (FFP) IG-COIL...

  • Page 95: Sensors

    1) Sensors Individual sensors detect engine operating conditions and sends signals regarding the information to ECU. Pulser Coil [Crank Position Sensor] Pulser coils function as crank position sensors. As flywheel rotates, two pulser coils detects crank position in 120 degree range of flywheel and sends the position signals to ECU.
  • Page 96 Fuel System (Fuel Injection) Throttle Position Sensor (TPS) Throttle position sensor is located on the top of throttle body, and is connected to throttle shaft. Throttle position sensor sends throttle open/close information to ECU. Oil Pressure Switch Oil pressure switch is located on the port side of ending, and is projected into oil passage to which pressure between crank shaft and cam shaft from oil pump is applied.

  • Page 97: Actuators

    2) Actuators Actuator section receives signals from ECU to control air/fuel ratio, ignition timing and idle revolution speed. ISC (Idle Speed Control) Valve ISC is also referred to as IAC (Idle Air Control). ISC valve is an electrical solenoid valve with built-in spring, and controls amount intake air that bypasses closed throttle valve.

  • Page 98: Control System (Ecu)

    Fuel System (Fuel Injection) 3) Control System (ECU) ECU requires 5VDC for operaiton. Accidental malfunction of ECU stops engine. ECU provides the following functions. 1. Calculates the most suitable fuel injection amount and ignition timing based on engine revolution speed, throttle position, intake vacuum, intake air temperature and engine cooling water temperature.

  • Page 99: Fuel Injection Timing

    (3) Fuel Injection Control ECU calculates intake air amount based on engine revolution speed and intake manifold pressure (intake vacuum pressure) to determine fuel injection amount. At engine starting, during warm-up, acceleration/deceleration, and idling, ECU performs correction control based on information from sensors.

  • Page 100: Starting Fuel Increase Correction

    Fuel System (Fuel Injection) 2) Starting Fuel Increase Correction At engine starting (cranking), amount of first fuel injection of each cylinder is increased (by extending injection period) to facilitate starting. In addition to this basic correction, information including cooling water temperature, atmospheric pressure and intake air temperature in the manifold from individual sensors are used to correct the engine operation to the best operating conditions.

  • Page 101: Warning Buzzer And Lamp (Led), And Control Of Engine Revolution Speed

    (6) Warning Buzzer and Lamp (LED), and Control of Engine Revolution Speed Warning System When an abnormality occurs on the engine, warning buzzer sounds and warning lamp (LED) is lit or blinks. In such case, engine speed is controlled but engine is not stopped. 1) Locations of warning buzzer and lamp (LED) •...

  • Page 102: Ignition System

    Fuel System (Fuel Injection) 5. Ignition System For ignition system, pointless CD ignition system is adopted, and ECU's electronic ignition timing control system controls the timing to the most suitable state according to current operating conditions. As engine is cranked, electric current is generated in the alternator's exciter coil and ECU charge coil, which is input to ECU's regulator to feed power needed for operations of ignition coil, fuel injector and fuel feed pump (FFP).

  • Page 103: Ignition Timing Controls

    (2) Ignition Control ECU's microcomputer is programmed with ignition timings best suited to engine's operating conditions. ECU obtains information about engine operating state such as revolution speed, throttle opening, manifold pressure (air intake vacuum pressure) and cooling water temperature based on the signals from the abovementioned sensors to generate ignition timing signal at the most suitable timings.

  • Page 104: Fuel Feed System

    Fuel System (Fuel Injection) (3) Fuel Feed System Fuel pump 4 (low pressure mechanical type) draws fuel from fuel tank 1, and feed it to fuel feed pump 6 (FFP) located in the vapor separator 5 through fuel connector 2 and fuel filter 3. Highly pressurized fuel passes through fuel cooler 7 and high pressure fuel filter 8, fed into fuel rail 9 and fuel injector 0, and then, injected into intake manifold.

  • Page 105: Components Of Fuel Feed System

    6. Components of Fuel Feed System 1) Fuel Pump (Low Pressure Mechanical Pump) Fuel pump is diaphragm pump that is operated mechanically by cam shaft. Pump base is plastic components shuts off heat of engine block to protect fuel pump from engine heat. a IN : Fuel from Filter/Tank b OUT : Fuel Outlet to Vapor Separator 2) Vapor Separator...

  • Page 106: Fuel Cooler

    Fuel System (Fuel Injection) 3) Fuel Regulator Fuel regulator located on the upper section of vapor separator serves to keep regular fuel pressure. Fuel regulator consists of diaphragm with built in spring that actuates valve/seat, and returns (pressurized) excessive fuel to vapor separator when the pressure exceeds certain value.

  • Page 107: Outline Of Fuel Injection System

    7. Outline of Fuel Injection System 1) Air Intake System Air intake system consists of components including intake manifold 1 (passage to cylinders that is coupled with common air chamber), throttle position sensor 3, throttle body/shutter 2, ISC (idle speed control) valve 4, MAP (manifold pressure) sensor 5, and MAT (manifold temperature) sensor 6.

  • Page 108: Inspection Items

    Fuel System (Fuel Injection) 8. Inspection Items 1) Inspection of Fuel Supply System Piping Check the fuel system piping for fuel leak, dirt, deterioration and damage, and replace or clear parts if necessary. 2) Inspection of Filter Check filter for dirt, build up of fuel slag, and fuel filter cup 2 for invasion of foreign matters and crack.
  • Page 109 Replacement of High Pressure Fuel Filter This filter cannot be disassembed. Replace every 200 hours or 2 years. • Disconnect fuel connector when performing this replacement work. • Attach filter in proper direction. • Be sure to use hose clip. Cleaning Fuel Feed Pump (FFP) Filter Remove filter 7 from fuel feed pump (FFP) located in the vapor separator, and clean filter 7.

  • Page 110: Inspection Of Fuel Pump

    Fuel System (Fuel Injection) 3) Inspection of Fuel Pump Remove fuel hoses (2) from fuel pump. Connect vacuum/pressure gauge to inlet of fuel pump. Close fuel pump outlet with a finger and apply specified pressure. Check if no air leaks. Vacuum/Pressure Gauge : P/N.

  • Page 111: Measuring Fuel Pressure

    5) Measuring fuel pressure Remove cap 1. Connect pressure gauge 2 as shown. WARNING • Before connecting pressure gauge, cover connection between pressure gauge and valve with clean and dry cloth to prevent fuel from releasing. • Connect pressure gauge securely. Pressure Gauge Ass'y : P/N.

  • Page 112: Inspection Of Fuel Regulator

    Fuel System (Fuel Injection) 6) Inspection of Fuel Regulator Remove cap 1. Connect pressure gauge 2 as shown. WARNING • Before connecting pressure gauge, cover connection between pressure gauge and valve with clean and dry cloth to prevent fuel from releasing. •...

  • Page 113: Draining Fuel

    7) Draining Fuel Remove cap 1. Connect pressure gauge ass'y as shown, place a vessel below pressure relief hose, and open pressure relief valve to release fuel pressure. WARNING Be sure to reduce fuel pressure in high pressure fuel passage before servicing fuel passage and/or vapor separator.

  • Page 114: Inspection Of Vapor Separator

    Fuel System (Fuel Injection) 9) Inspection of Vapor Separator Check needle valve for bend and wear. Replace if necessary. Check float for deformation. Replace if necessary. Check filter for dirt and clogging. Clean if necessary. Reinstall needle valve, float and float pin, and check that the parts moves smoothly.

  • Page 115: Reassembly Of Vapor Separator

    10) Reassembly of Vapor Separator Attach float chamber to vapor separator. Reassemble all parts that were removed. Check that hose is reconnected correctly. 11) Inspection of ISC (Idle Speed Control) Use diagnosis system to check operation of ISC (Idle Speed Control) valve.
  • Page 116 Fuel System (Fuel Injection) 4-34 25/30 2006...

  • Page 117: Power Unit

    Power Unit 1 Special Tools 15) Inspection of Cam Shaft ……………… 5-38 ……………………………… 5-2 2 Parts Layout 16) Inspection of Cylinder Head …………… 5-39 ……………………………… 5-3 17) Inspection of Oil Pump ………………… 5-40 Engine …………………………………………… 5-3 18) Installation of Valves …………………… 5-41 Recoil Starter ……………………………………...

  • Page 118: Special Tools

    Power Unit 1.Special Tools Piston Slider Compression Gauge Torque Wrench Valve Clearance Driver P/N. 3AC-99071-0 P/N. 3AC-72871-0 P/N. 3AC-99030-0 P/N. 3AC-99070-0 Measuring compression Installing piston Adjusting valve clearance Adjusting valve clearance pressure Oil Filter Wrench Crankshaft Holder 2 Valve Spring Compressor Flywheel Holder P/N.

  • Page 119: Parts Layout

    2. Parts Layout Engine 30 Nám (22 lbáft) [3.0 kgfám] Ref. Description Remarks Q'ty Power Unit Oil Level Gauge Gasket Do not reuse. Dowel Pin Bolt 6 M8 L=105mm Apron Screw 2 M6 L=60mm Recoil Starter Belt Cover 10 Battery Cable 25/30 2006...

  • Page 120: Recoil Starter

    Power Unit Recoil Starter P/L Fig. 11 1-15 1-13 1-12 1-11 1-10 1342 6 Nám ( lbáft) [0.6 kgfám] 1342 1342 1342 1342 1342 Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Recoil Starter 10 Belt Cover 1-1 Starter Case 11 Collar, 6.2-9-12.3 1-2 Starter Spring 12 Bolt...

  • Page 121: Magneto & Ecu

    Magneto & ECU P/L Fig. 8 150 N·m (108 lb·ft) [15.0 kgf·m] 6 N·m (4 lb·ft) [0.6 kgf·m] 1342 1342 Fig.2 6 N·m (4 lb·ft) [0.6 kgf·m] 13-1 16-1 1342 1342 22 20 27-1 1342 1342 1342 Ref. Ref. Description Remarks Description Remarks...

  • Page 122: Electric Parts

    Power Unit P/L Fig. 9 Electric Parts 22 Nám (16 lbáft) [2.2 kgfám] 31-1 13 Nám (9 lbáft) [1.3 kgfám] 53-1 8 Nám (6 lbáft) [0.8 kgfám] 1342 1342 1342 1741 1741 1741 13 Nám (9 lbáft) [1.3 kgfám] o Intake Manifold o Intake Silencer 1342 1342...
  • Page 123 P/L Fig. 9 Electric Parts 22 Nám (16 lbáft) [2.2 kgfám] 31-1 13 Nám (9 lbáft) [1.3 kgfám] 53-1 8 Nám (6 lbáft) [0.8 kgfám] 1342 1342 1342 1741 1741 1741 13 Nám (9 lbáft) [1.3 kgfám] o Intake Manifold o Intake Silencer 1342 1342...

  • Page 124: Fuel Pump, Fuel Rail, Vapor Separator

    Power Unit Fuel Pump, Fuel Rail, Vapor Separator P/L Fig. 5 23-4 23-6 23-3 4st OIL 23-2 23-5 23-1 6 N·m (4 lb·ft) [0.6 kgf·m] 4st OIL 4st OIL 28-1 28-2 6 N·m (4 lb·ft) [0.6 kgf·m] Air Vent R/Mount To Fuel Pump Bottom Cowl Cylinder Block...
  • Page 125 P/L Fig. 5 Fuel Pump, Fuel Rail, Vapor Separator 23-4 23-6 23-3 4st OIL 23-2 23-5 23-1 6 N·m (4 lb·ft) [0.6 kgf·m] 4st OIL 4st OIL 28-1 28-2 6 N·m (4 lb·ft) [0.6 kgf·m] Air Vent R/Mount To Fuel Pump Bottom Cowl Cylinder Block To Fuel Rail...
  • Page 126 Power Unit Fuel Pump, Fuel Rail, Vapor Separator P/L Fig. 5 10-16 10-13 10-15 10-14 4st OIL 4st OIL 10-11 10-2 4st OIL 10-18 10-10 10-6 10-4 10-7 17-3 10-3 10-12 10-5 10-12-1 17-1 10-1 4st OIL 4st OIL 17-1 17-2 17-2 17-1...

  • Page 127: Intake Manifold

    P/L Fig. 4 Intake Manifold 9 Nám (7 lbáft) [0.9 kgfám] 6 Nám (4 lbáft) [0.6 kgfám] 4st OIL 4st OIL 4st OIL Ref. Ref. Description Remarks Description Remarks Q'ty Q'ty Intake Manifold 20 Bolt 2 M6 L=12mm 1-1 Bolt, 5-10 21 Intake Silencer Ass'y 1 for ISC Valve 1-2 Washer, 5.3-12-1...

  • Page 128: Cam Shaft & Oil Pump

    Power Unit Cam Shaft & Oil Pump P/L Fig. 6 11 Nám (8 lbáft) [1.1 kgfám] 27 Nám (20 lbáft) [2.7 kgfám] 1342 1342 1342 64 Nám (46 lbáft) [6.4 kgfám] 1342 4st OIL 1342 1342 4st OIL 4st OIL 9 Nám (7 lbáft) [0.9 kgfám] Ref.

  • Page 129: Cylinder Head

    Cylinder Head P/L Fig. 1 10 Nám ( 7 lbáft) [1.0 kgfám] 30 Nám (22 lbáft) [3.0 kgfám] 6 Nám (4 lbáft) [0.6 kgfám] 6 Nám (4 lbáft) [0.6 kgfám] 9 Nám (7 lbáft) [0.9 kgfám] 1342 1342 1342 4st OIL Intake Silencer 1373B 1373B...

  • Page 130: Intake Valve & Exhaust Valve

    Power Unit Intake Valve & Exhaust Valve P/L Fig. 7 7 Nám (5 lbáft) [0.7 kgfám] 7 Nám (5 lbáft) [0.7 kgfám] 4st OIL 7 Nám (5 lbáft) [0.7 kgfám] 4st OIL 7 Nám (5 lbáft) [0.7 kgfám] 7 Nám (5 lbáft) [0.7 kgfám] 4st OIL 4st OIL 7 Nám (5 lbáft) [0.7 kgfám]...

  • Page 131: Cylinder

    Cylinder P/L Fig. 2 23 Nám ( 7 lbáft) [2.3 kgfám] 1141C 1141C 1141C 4st OIL 0 Nám ( 7 lbáft) [ .0 kgfám] 23.5 Nám ( 7 lbáft) [2.4 kgfám] 4st OIL 8 Nám ( 3 lbáft) [ .8 kgfám] 30 Nám (22 lbáft) [3.0 kgfám] 1342 1342...

  • Page 132: Piston & Crankshaft

    Power Unit Piston & Crankshaft P/L Fig. 3 4st OIL 4st OIL 4st OIL 4st OIL UP mark 10-1 6 Nám (4 lbáft) [0.6 kgfám] 12 Nám (9 lbáft) [1.2 kgfám] 4st OIL LR-101 Ref. Description Remarks Q'ty Crankshaft Ass'y Metal (Red) Metal (Blue) Piston...

  • Page 133: Top Cowl

    Top Cowl P/L Fig. 23 Ref. Description Remarks Q'ty Top Cowl 1 Motor Cover (Upper) 1-1 Top Cowl Seal 1-2 Roller, 6.1-14.7-14 1-3 Washer, 6-16-1.5 1-4 E-Ring, d=5 1-5 Tilt Handle 1-6 Washer, 6-16-1.5 1-7 Nut Decal Set Caution Decal "A" 25/30 2006 5-17...

  • Page 134: Inspection Items

    Power Unit 3. Inspection Items 1) Inspection of Compression Pressure Run engine 5 minutes to warm up, and then stop. Shift gear into neutral (N). Remove lock plate from stop switch. CAUTION Remove lock plate from stop switch before measuring compression pressure. This will prevent engine from accidental starting.

  • Page 135: Inspection Of Oil Pressure

    2) Inspection of Oil Pressure Spread rag below oil pressure switch. Remove oil pressure switch and connect oil pressure gauge 1 to switch hole. Use commercially available oil pressure gauge. Use the instrument applicable to 1 Mpa (142 PSI ) [ 10 kgf/cm Start engine and run 5 minutes to warm up at idling revolution speed.

  • Page 136: Inspection Of Valve Clearance

    Power Unit 3) Inspection of Valve Clearance Remove upper starter lock cable, and then recoil starter and belt cover. Disconnect breather hoses 1 (2). Remove fuel pump 2. Disconnect cooling water (fuel cooler) hoses (2). Disconnect spark plug caps and ignition coils, and remove spark plugs and cylinder head cover 3.
  • Page 137 Loosen rocker arm lock nut 6, and turn adjusting screw 7 to set valve clearance to specified value. • Turning adjust screw 7 clockwise makes valve clearance smaller. • Turning adjust screw 7 counterclockwise makes valve clearance larger. Valve Clearance Driver 8 : P/N.

  • Page 138: Removing Power Unit

    Power Unit 4) Removing Power Unit å Disconnect upper and lower starter lock cables. Remove recoil starter, belt cover and starter pulley. Loosen flywheel nut. Loosen flywheel nut before removing power unit to make the work easier. å Flywheel Holder : ∫...
  • Page 139 Disconnect PTT switch coupler 4 . (PTT Model) Disconnect throttle link rod 5. Remove oil level gauge 6. Disconnect lower breather hose 7. Disconnect cooling water (fuel cooler) hose 8 and fuel hose 9. Remove apron q by removing bolts 0 (2). Remove power unit by removing bolts w (6) and then lifting it.
  • Page 140 Power Unit Remove flywheel and key. å å Flywheel Holder : P/N. 3AC-99200-0 å Flywheel puller : Use puller contained in the following puller kit. ∫ Flywheel puller kit : P/N. 3C7-72211-1 CAUTION Apply forces to tools toward directions as shown, and perform work taking care not to allow flywheel holder to remove.

  • Page 141: Removing Timing Belt And Pulley

    5) Removing Timing Belt and Pulley Turn timing pulley 1 clockwise to bring " " mark a of belt guide to " " mark b of cylinder block, and check that " " mark c of cam shaft pulley 2 and " " mark d of cylinder head are aligned with each other.

  • Page 142: Inspection Of Timing Belt

    Power Unit Remove cam shaft pulley 8 bolt 9, and then, remove cam shaft pulley 8. When loosening cam shaft pulley bolt, be careful not to turn cam shaft pulley. Remove nut 0, lock washer q, belt guide w, timing pulley e and key r.

  • Page 143: Installation Of Pulley And Timing Belt

    7) Installation of Pulley and Timing Belt " mark a of cam shaft Install cam shaft pulley, bring " pulley 1 to " " mark of cylinder head, and then, tighten bolt 2 to specified torque. No.1 piston is to be at top dead center of compression stroke.
  • Page 144 Power Unit Face part number side of timing belt 9 up, align locating ▲ ● lines a of the belt as shown, and engage belt with timing pulley and then with cam shaft pulley. CAUTION • Be careful not give damage to timing belt when installing.
  • Page 145 Turn timing pulley t clockwise twice, and check that locating marks a and b, and c and d of pulleys t and y are aligned with each other respectively. Loosen belt tensioner u bolt. Turn timing pulley t approximately 25 degrees counterclockwise to move belt tensioner u until cam shaft pulley y shifts one 11°...

  • Page 146: Removing Cylinder Head

    Power Unit 8) Removing Cylinder Head • No.1 piston is to be at top dead center of compression stroke. • Removal or installation of parts can be made easier when some of them are assembled together. Remove power unit. (Refer to the section for removing power unit.) Air ent R/Mount...
  • Page 147 Remove cylinder head bolts in the reverse sequence of order shown, and remove cylinder head. CAUTION Do not scratch or give damage to mating surfaces of cylinder head and cylinder block. Remove oil pump ass'y 1. Loosen rocker arm lock nut, and loosen adjusting screw as much as possible.

  • Page 148: Inspection Of Valve Spring

    Power Unit Compress valve spring 4 by using compressor 6, remove cotter, and then, spring and valve. Valves, springs and other related parts should be arranged in the order they are removed. Valve Spring Compressor 6 : P/N. 3AC-99075-0 9) Inspection of Valve Spring Measure valve spring free length a.

  • Page 149: Inspection Of Valve

    10) Inspection of Valve Check valve for dent and wear on the face. Replace if necessary. Measure valve stem outer diameter b. Replace if the diameter is less than specified value. Valve Stem Outer Diameter b : Standard Value Intake Side : 5.48 mm ( 0.216 in ) Exhaust Side : 5.46 mm ( 0.215 in ) Functional Limit : Intake Side : 5.46 mm ( 0.215 in )

  • Page 150: Inspection Of Valve Seat

    Power Unit 12) Inspection of Valve Seat Remove carbon built up on the valve. Apply thin coat of red lead on the valve seat. Use valve lapper (commercially available item) as shown to push valve onto valve seat lightly. Measure width of area where valve face contacted with valve seat a that can be identified with red lead adhered to valve face.

  • Page 151: Correction Of Valve Seat

    13) Correction of Valve Seat Use valve seat cutter (commercially available item) to correct valve seat. 0û 45û 60û Turn 45 degree cutter clockwise to cut valve seat surface to make it smooth. Be careful not to over-cut valve seat. Turn valve seat cutter while pushing down evenly.
  • Page 152 Power Unit Use 45 degree cutter to adjust contact width of valve seat c to specified value. 45˚ b Width before correction c Specified width Valve seat contact area is located on the center, which should be adjusted to specified value by cutting upper and lower ends by using 30 degree and 60 degree seat cutters 30˚...

  • Page 153: Inspection Of Rocker Arm And Rocker Arm Shaft

    Apply thin coat of abrasive compound on the overall valve seat contact area, and turn valve lapper (commercially available item) while tapping valve. CAUTION Perform the work by taking care not to allow abrasive compound to adhere to valve stem and valve guide. •...

  • Page 154: Inspection Of Cam Shaft

    Power Unit 15) Inspection of Cam Shaft Measure cam height. Replace if the height is less than specified value. Cam Height at Both Intake and Exhaust Sides a : Standard Value 25 : 23.87 mm ( 0.9498 in ) 30 : 24.28 mm ( 0.9559 in ) Functional Limit : Cam Height at Both Intake and Exhaust Sides a 25 : 23.60 mm ( 0.9291 in ) 30 : 24.00 mm ( 0.9449 in )

  • Page 155: Inspection Of Cylinder Head

    16) Inspection of Cylinder Head Remove carbon build-up of combustion chamber, and check for deterioration. Use straight edge 1 and thickness gauge 2 to check distortion of cylinder head in the directions shown. Replace if the distortion is over specified value. Cylinder Head Distortion Limit : 0.10 mm ( 0.004 in ) 25/30 2006...

  • Page 156: Inspection Of Oil Pump

    Power Unit 17) Inspection of Oil Pump Use micrometer, cylinder gauge, depth gauge and thickness gauge to measure dimensions shown below. Replace oil pump if over specified value. Functional Limit : Clearance between Outer Rotor and Body a : 0.25 mm ( 0.0098 in ) Clearance between outer and inner rotors b : 0.16 mm ( 0.0063 in ) Clearance between sides of rotor and body c :...

  • Page 157: Installation Of Valves

    18) Installation of Valves Apply oil to valve guide and attach new valve stem seal. 4st OIL Intake Side : Black Exhaust Side : Green Install valve 2, valve spring seat 3, valve spring 4 and retainer 5 in the order shown, and then, attach valve spring compressor 6.

  • Page 158: Installation Of Cam Shaft

    Power Unit 19) Installation of Cam Shaft Apply engine oil to periphery of new oil seal and install it. Driver Rod : P/N. 3AC-99702-0 Oil Seal Attachment : P/N. 3AC-99820-0 Apply grease to lip of oil seal before installing it. Install cam shaft 2 from direction shown.

  • Page 159: Installation Of Oil Pump

    Tighten rocker arm shaft locating bolt 6 to specified torque. Rocker Arm Shaft Bolt : 9 N·m ( 7 lb·ft ) [ 0.9kgf·m ] 21) Installation of Oil Pump Align cuts of oil pump drive shaft a and cam shaft pin b with each other to install oil pump 1.

  • Page 160: Installation Of Cylinder Head

    Power Unit 22) Installation of Cylinder Head No.1 piston is to be at top dead center of compression stroke. " mark a of After installing cam shaft pulley, bring " pulley 1 to " " mark b of cylinder head. Check that "...

  • Page 161: Disassembly Of Cylinder Block

    23) Disassembly of Cylinder Block Remove thermostat cover bolt and the cover 1. Remove oil filter 2. Wipe off spilt oil completely. Oil Filter Wrench : P/N. 3AC-99090-0 Loosen crank case bolts in several steps in the reverse sequence of order shown, and remove crank case. Remove connecting rod bolts 3 and connecting rod cap 4, and then, crankshaft 5 and oil seal.

  • Page 162: Inspection Of Piston Outer Diameter

    Power Unit 24) Inspection of Piston Outer Diameter Measure piston outer diameter between points specified. Replace if the diameter is less than specified value. Piston Outer Diameter a : Standard Value 60.96 mm ( 2.4000 in ) Measurement Points b : 9mm ( 0.35 in ) above piston skirt bottom Functional Limit : 60.90 mm ( 2.3976 in )

  • Page 163: Inspection Of Piston Ring Side Clearance

    27) Inspection of Piston Ring Side Clearance Measure piston side clearance. Replace piston and piston rings as a set if the clearance is over specified value. Piston Side Clearance : Top Ring a : 0.04 to 0.08mm ( 0.0016 to 0.0031 in ) Second Ring b : 0.03 to 0.07mm ( 0.0012 to 0.0028 in ) Oil Ring c : 0.05 to 0.15mm ( 0.0020 to 0.0059 in ) Functional Limit :...

  • Page 164: Inspection Of Piston Pins

    Power Unit 29) Inspection of Piston Pins Measure piston pin outer diameter. Replace piston pin if outer diameter is less than specified value. Piston Pin Outer Diameter : Standard Value 16.00 mm ( 0.6299 in ) Functional Limit : 15.97 mm ( 0.6287 in ) Measure piston pin boss inner diameter a.

  • Page 165: Inspection Of Crankshaft

    32) Inspection of Crankshaft Measure crankshaft journal outer diameter a and crank pin outer diameter b. Replace crankshaft if either outer diameter is less than specified value. Crankshaft Journal Outer Diameter a : Standard Value 35.99 mm ( 1.4169 in ) Crank Pin Outer Diameter b : Standard Value 29.98mm ( 1.1803 in ) Functional Limit :...

  • Page 166: Inspection Of Crank Pin Oil Clearance

    Power Unit 33) Inspection of Crank Pin Oil Clearance Clean connecting rod. Place cylinder block upside down on the work bench. Install piston to connecting rod 1. Do not attach piston rings. Install crankshaft on the cylinder block. Place plasti-gauge 3 on each crank pin 4 parallel to crankshaft.

  • Page 167: Inspection Of Crank Shaft Main Journal Oil Clearance

    34) Inspection of Crank Shaft Main Journal Oil Clearance Clean bearings, crankshaft main journal, and bearing installation areas of crank case and cylinder block. Place cylinder block on the work bench with cylinder head side facing downward. Install bearing 1 and crankshaft 2 to cylinder block 3. •...

  • Page 168: Inner Diameter Of Cylinder/Crank Case Bearing Holder (Inner Diameter Code)

    Power Unit Loosen bolts in reverse order in several steps. Remove crank case and measure width of crushed plasti-gauge on each main journal. Replace bearing if the width is over specified value. Crankshaft Main Journal Oil Clearance : 0.012 to 0.044 mm ( 0.00047 to 0.00173 in ) Functional Limit : 0.060 mm ( 0.00236 in ) If the clearance is less than specified value,...

  • Page 169: Assembling Piston And Connecting Rod

    37) Assembling Piston and Connecting Rod Install connecting 2, piston pin 3, and piston pin clip 4 to piston 1. • Point "3RO-UP" mark of connecting rod a and "UP" mark b of piston at the same direction. • Be sure to use new piston pin clip, and place clip gap away from piston pin groove c as shown.
  • Page 170 Power Unit Put pistons into cylinder with piston crown 1 "UP" mark directing flywheel side and piston slider 6 set on the pistons. Before installing, apply engine oil to piston peripheral surfaces, piston rings and piston sliders. Piston Slider 6 : P/N.
  • Page 171 Install bearing half to crank case. • Be sure that individual bearings are installed to their original locations. • Install bearings with their projection fit into crank case groove. Apply 4 stroke engine oil to bearings. Apply sealing agent to mating surface of crank case (both sides, overall).
  • Page 172 Power Unit Install oil filter and tighten it to specified torque by using oil filter wrench. Apply thin coat of engine oil to O-ring before 4st OIL installing oil filter. Oil Filter Wrench : P/N. 3AC-99090-0 Oil Filter : 18 N·m ( 13 lb·ft ) [ 1.8 kgf·m ] Install thermostat, new gasket and thermostat cover r.

  • Page 173: Installation Of Power Unit

    38) Installation of Power Unit Clean power unit mating surface, and install dowel pin 1 and gasket 2. Install power unit 3, and tighten bolts 4 in two or three steps to specified torque. Power Unit Installation Bolt : 30 N·m ( 22 lb·ft ) [ 3.0 kgf·m ] Install apron 5.
  • Page 174 Power Unit Reconnect warning lamp, start switch and stop switch. (Tiller Handle Model) Reconnect remote control harness coupler. (Remote Control Model) Install key and flywheel. CAUTION Apply forces to tools toward directions as shown, and perform work taking care not to allow flywheel holder to remove.

  • Page 175: Removing Recoil Starter

    39) Removing Recoil Starter Adjustment of Starter Lock Cable Shift gear into neutral (N). Check that maximum diameter section of slide 1 is at neutral start mark 2. If not, adjust lower side of cable. 1 Slide Perform shift operation to check that recoil starter is locked 2 Neutral Start Mark at other than neutral (N) position.

  • Page 176: Inspection Of Recoil Starter

    Power Unit Remove E-ring 5, and then, ratchet 7, ratchet guide 8, and return spring 9. 5 E-Ring 8 Ratchet Guide 6 Reel 9 Return Spring 7 Ratchet Remove starter spring w. It is not necessary to remove starter spring from starter case if it is not necessary to replace it.

  • Page 177: Installation Of Recoil Starter

    42) Installation of Recoil Starter Reverse disassembly procedure to assemble by taking care of the following matters. When setting starter spring into starter case, face starter spring outer edge hook to the right and set it into peripheral cut of starter case. Run starter rope through rope guide 1.
  • Page 178 Power Unit 5-62 25/30 2006...

  • Page 179: Lower Unit

    Lower Unit 1 Special Tools 17) Disassembly of Clutch Cam and Cam Rod … 6-15 ……………………………… 6-2 2 Parts Layout …………………………… 18) Inspection of Cam Rod and Clutch Cam … 6-16 19) Assembly of Cam Rod and Clutch Cam… 6-16 Gear Case ………………………………………...

  • Page 180: Special Tools

    Lower Unit 1.Special Tools Bevel Gear B Nut Wrench Bevel Gear B Nut Socket Spring Pin Tool A Spring Pin Tool B P/N. 346-72231-0 P/N. 346-72232-0 P/N. 345-72227-0 P/N. 345-72228-0 Removing spring pin Installing spring pin Removing/installing Pinion Nut (B Gear Nut) Bevel Gear Bearing Installation Tool Thickness Gauge Bevel Gear Bearing Puller Ass'y...
  • Page 181 Bearing Installation Tool Center Bolt Universal Puller Plate Bearing attachment P/N. 3AC-99738-0 P/N. 3AC-99750-0 P/N. 3AC-99900-0 P/N. 3AC-99905-0 Removing reverse Used with driver rod Attaching Removing propeller shaft Installing drive shaft bearing gear/bearing reverse gear (C gear) bearing housing Center Plate 2 Driver Rod 2 Needle Bearing Attachment 2 P/N.

  • Page 182: Parts Layout

    Lower Unit P/L Fig. 14 2.Parts Layout Gear Case 19 N·m (14 lb·ft) [1.9 kgf·m] 13 N·m (9 lb·ft) [1.3 kgf·m] 19 N·m (14 lb·ft) [1.9 kgf·m] 1342 1342 1342 1342 1342 1342 1342 1342 1342 18-2 GEAR GEAR GEAR 19 N·m (14 lb·ft) [1.9 kgf·m] 1342 1342...

  • Page 183: Drive System & Water Pump

    P/L Fig. 15 Drive System & Water Pump 6 N·m (4 lb·ft) [0.6 kgf·m] 1342 1342 1342 Fig. 13 35 N·m (25 lb·ft) [3.5 kgf·m] 1373B 1373B 1373B 1373B 1342 1342 1342 1373B 25 N·m (18 lb·ft) [2.5 kgf·m] 1373B 1373B 1373B aProjection bHole...
  • Page 184 Lower Unit P/L Fig. 15 Drive System & Water Pump 6 N·m (4 lb·ft) [0.6 kgf·m] 1342 1342 1342 Fig. 13 35 N·m (25 lb·ft) [3.5 kgf·m] 1373B 1373B 1373B 1373B 1342 1342 1342 1373B 25 N·m (18 lb·ft) [2.5 kgf·m] 1373B 1373B 1373B...

  • Page 185: Shift

    P/L Fig. 16 Shift 6 N·m (4 lb·ft) [0.6 kgf·m] GEAR GEAR GEAR GEAR GEAR GEAR Ref. Description Remarks Q'ty Clutch Cam Cum Rod "S" Cam Rod "L" Cam Rod "UL" Spring Pin, 3-12 Cam Rod Bushing O Ring, 2.4-5.8 Do not reuse.

  • Page 186: Inspection Items

    Lower Unit 3. Inspection Items 1) Draining Gear Oil Drain gear oil. Refer to "Replacement of Gear Oil" in Chapter 3. 2) Removing Propeller Shift gear into neutral (N). Put a piece of wooden block between anti-cavitation plate and propeller 4 to prevent rotation of propeller, and remove propeller nut 2 and then propeller.

  • Page 187: Removing Lower Unit

    3) Removing Lower Unit Removal of lower unit does not require removal of power unit from outboard motor body. Remove spring pin and disconnect shift rod. • Disconnect shift rod at lower side of shift rod joint 1. • Use spring pin tool A 2 to remove spring pin. •...

  • Page 188: Inspection Of Water Pump

    Lower Unit 5) Inspection of Water Pump Check pump case (upper) 1 for deformation. Replace if necessary. Check impeller 2 and pump case liner 3 for crack and wear. Replace if necessary. Check key 4, water pump guide plate 5 and drive shaft groove a for wear.

  • Page 189: Disassembly Of Propeller Shaft Ass'y

    7) Disassembly of Propeller Shaft Ass'y Push small bladed screw driver into clutch pin snap 1 to remove it while rotating propeller shaft. Then, push clutch pin 2 lightly while apply preload to push rod 4 to pull out the pin.

  • Page 190: Disassembly Of Propeller Shaft Housing

    Lower Unit 10) Disassembly of Propeller Shaft Housing Tighten universal puller plate to make gap between reverse gear (C gear) and propeller shaft housing. Universal Puller Plate : P/N. 3AC-99750-0 Remove reverse gear (C gear) ass'y by putting two bladed screw drivers into the gap to force the gap to open.

  • Page 191: Inspection Of Propeller Shaft Housing

    When removing only oil seal, use bladed screw driver to pry apart. 11) Inspection of Propeller Shaft Housing Use cleaning oil and cleaning brush to clean propeller shaft housing, and check it for crack or damage. Replace if necessary. Check reverse gear (C gear) teeth and clutch for crack or damage.

  • Page 192: Assembly Of Propeller Shaft Housing

    Lower Unit 12) Assembly of Propeller Shaft Housing Use a press to push new needle bearing into propeller shaft bearing to specified depth. • Install needle bearing with manufacturer's marking a facing reverse gear (C gear) side. • Screw needle bearing attachment 2 into driver rod 1 gently by using hand without making gap.

  • Page 193: Removing Pump Case (Lower)

    13) Removing Pump Case (Lower) Remove pump case (lower). 14) Disassembly of Pump Case (Lower) Use bladed screw driver to remove oil seal 1. 1 Oil seal Do not reuse. 15) Assembly of Pump Case (Lower) Apply engine oil to periphery of new oil seal, and install into pump case (lower) with number side facing downward.

  • Page 194: Inspection Of Cam Rod And Clutch Cam

    Lower Unit 18) Inspection of Cam Rod and Clutch Cam Check cam rod 1 and clutch cam 2 for crack and wear. Replace if necessary. GEAR GEAR GEAR 19) Assembly of Cam Rod and Clutch Cam Reassemble. Be careful of direction of cam rod. 20) Removing Drive Shaft Remove pinion nut (B gear nut), remove drive shaft ass'y 1 and pinion gear (B gear) 2, and draw out forward gear (A...

  • Page 195: Inspection Of Drive Shaft

    22) Inspection of Drive Shaft Check drive shaft for bend and wear. Replace if necessary. Measure drive shaft runout. Runout Limit : 0.5 mm (0.020 in) a Supporting Points 23) Disassembly of Forward Gear (A Gear) Use two bladed screw driver to remove taper roller bearing from forward gear (A gear).

  • Page 196: Assembly Of Drive Shaft

    Lower Unit 26) Assembly of Drive Shaft Attach pinion nut (B gear nut) 1 to drive shaft 2 temporarily. Use a press to attach new drive shaft bearing to drive shaft 2. Bearing Installation Tool 3 : P/N. 3AC-99900-0 CAUTION •...

  • Page 197: Inspection Of Gear Case

    28) Inspection of Gear Case Check skeg area a and torpedo-like area b for crack and damage. Replace if necessary. 29) Assembly of Lower Unit Perform shim adjustment when taper roller bearing, gear, drive shaft, propeller shaft or gear case is replaced. GEAR GEAR GEAR...

  • Page 198: Installation Of Pinion Gear (B Gear)

    Lower Unit Install spring guide 5. Install new taper roller bearing (outer race) 6. Perform shim adjustment when taper roller bearing, gear, drive shaft, propeller shaft or gear case is replaced. 346-72733-0 3B7-72731-0 Bearing Outer Press Kit : P/N. 3B7-72739-0 346-72732-0 30) Installation of Pinion Gear (B Gear) After installing forward gear (A gear), install drive shaft ass'y...

  • Page 199: Settling Pinion Gear (B Gear) Height

    31) Settling Pinion Gear (B Gear) Height Perform backlash measurement and shim adjustment after "Settling Pinion Gear (B Gear) Height". CAUTION Read description of all steps before attempting shim thickness change. Perform shim adjustment when taper roller bearing, gear, drive shaft, propeller shaft or gear case is replaced.
  • Page 200 Lower Unit Install pump case (lower) and gasket to guide plate. (Secure guide plate with small bolts 5.) Use four short bolts 5. M6 P1.0 L=30 mm Short Bolts for Inspection 5 : 6 N·m ( 4 lb·ft ) [ 6 kgf·m ] Put shimming gauge 2 6 into gear case, and lay down gear case by 90 degrees as shown.
  • Page 201 Insert thickness gauge 8 into cut a of shimming gauge 2 6 to measure pinion gear (B gear) height, while pulling up the drive shaft in the direction shown by arrow. Thickness Gauge 8 : P/N. 353-72251-0 Pinion Gear (B Gear) Height Clearance : 0.60 to 0.64 mm ( 0.0236 to 0.0252 in ) When clearance is within specified range, go to next section "Settling Forward Gear (A Gear) Backlash".

  • Page 202: Settling Forward Gear (A Gear) Backlash

    Lower Unit 32) Settling Forward Gear (A Gear) Backlash Backlash Measuring Tool Kit : P/N. 3C8-72234-0 Shaft 1 : P/N. 345-72723-0 O-Ring 2 : P/N. 332-60002-0 Collar 3 : P/N. 346-72245-0 Plate 4 : P/N. 3A3-72713-0 Conical Disc Spring 5 : P/N.
  • Page 203 • As an alternative to the above measuring tool, a tool used for pulling out the following propeller shaft housing can be used to secure forward gear (A gear). • When performing the work, assemble propeller shaft ass'y and housing ass'y and bolts to tighten to specified torque.
  • Page 204 Lower Unit Keep the following matters in mind when 6&7 performing the measurement. • Shaft 1 that secures forward gear (A gear) has been tightened so that drive shaft q cannot be turned over backlash when it is turned lightly. •...

  • Page 205: Reassembly Of Pinion Gear Nut (B Gear Nut)

    33) Reassembly of Pinion Gear Nut (B Gear Nut) After installing drive shaft ass'y 1, pinion gear (B gear) 2 and pinion nut (B gear nut), and tighten the nut to specified torque. Bevel Gear B Nut Socket 3 : P/N.

  • Page 206: Reassembly Of Pump Case (Lower)

    Lower Unit 35) Reassembly of Pump Case (Lower) Remove pump case (lower) and apply OBM grease to oil seal. Attach new O-ring 1 and pump case (lower) 2. 36) Assembly of Water Pump Attach new gaskets 1 and 2, water pump guide plate 3 and dowel pin 4.
  • Page 207 Install pump case (upper) ass'y 9 on the gear case, and tighten bolts 0 in two or three steps to specified torque. Apply grease in the interior of pump case liner, and install pump case (upper) by pushing it down with hand while turning drive shaft 1342 1342 1342...

  • Page 208: Installation Of Lower Unit

    Lower Unit 37) Installation of Lower Unit Set cam rod to reverse (R) position. Connect water pipe securely. Move flywheel a little or shift gear into reverse (R), install propeller, and turn propeller shaft counterclockwise to engage spline. Attach lower unit ass'y to drive shaft housing, and tighten lower unit installation bolts 1 to specified torque.
  • Page 209 Set both engine side and gear case side gear shifts to neutral (N). Connect shift rod and cam rod with new spring pin. Spring Tool 3 : P/N. 345-72228-0 WARNING • Before removing or installing propeller, be sure to disconnect battery cables from battery and remove stop switch lock plate.
  • Page 210 Lower Unit 6-32 25/30 2006...

  • Page 211: Bracket

    Bracket 1 Special Tools 12) Removing Clamp Bracket (PTT or Gas Assistant Model) … 7-21 ……………………………… 2 PTT Wiring and Layout Diagram 13) Removing Clamp Bracket (Mechanical Tilt Model) … 7-21 …… 3 Parts Layout 14) Installation of Clamp Bracket (PTT or Gas Assistant Model) … 7-22 …………………………………...

  • Page 212: Special Tools

    Bracket 1.Special Tools 346-72761-0 345-72762-0 345-72763-0 940191-1000 930191-1000 Mount Puller Kit P/N. 361-72760-0 Removing upper mount 25/30 2006...

  • Page 213: Ptt Wiring And Layout Diagram

    2.PTT Wiring and Layout Diagram Battery PTT Solenoid Switch (UP) Switch Wiring Colors R : Red B : Black PTT Solenoid Sb : Sky Blue Switch (DN) P : Pink L : Blue G : Green Circuit Breaker PTT Motor Tilt Cylinder Shock Blow Valve Change Over Valve &...

  • Page 214: Parts Layout

    Bracket P/L Fig. 13 3.Parts Layout 31 N·m (22 lb·ft) [3.1 kgf·m] Drive Shaft Housing 30 N·m (22 lb·ft) [3.0 kgf·m] 1741 1741 1741 30 N·m (22 lb·ft) [3.0 kgf·m] 31 N·m (22 lb·ft) [3.1 kgf·m] 19 N·m (14 lb·ft) [1.9 kgf·m] 24 N·m (17 lb·ft) [2.4 kgf·m] 1342 1342...

  • Page 215: Swivel Bracket (Mechanical Tilt)

    P/L Fig. 19 Swivel Bracket (Mechanical Tilt) 6 N·m (4 lb·ft) [0.6 kgf·m] 1342 1342 6 N·m (4 lb·ft) [0.6 kgf·m] 1342 12-2 21 N·m (15 lb·ft) [2.1 kgf·m] 12-1 1342 1342 1342 40 N·m (29 lb·ft) [4.0 kgf·m] Lower Mount Rubber Cap 6 N·m (4 lb·ft) [0.6 kgf·m] 1342...

  • Page 216: Clamp Bracket & Reverse Lock

    Bracket P/L Fig. 18 Clamp Bracket & Reverse Lock 11 N·m (8 lb·ft) [1.1 kgf·m] 1342 1342 1342 Swivel Bracket 12-1 12-3 12-2 24 N·m (17 lb·ft) [2.4 kgf·m] 27 N·m (20 lb·ft) [2.7 kgf·m] 1342 1342 1342 1342 1342 1342 Ref.

  • Page 217: Bracket, Ptt & Gas Assistant

    P/L Fig. 20 Bracket, PTT & Gas Assistant 43-6 43-7 43-5 43-2 43-4 43-3 11-1 24 N·m (17 lb·ft) [2.4 kgf·m] 11-2 43-7 11 N·m (8 lb·ft) [1.1 kgf·m] Trim Meter 43-1 43-2 Trim Meter Kit (43-1∼43-7) Ref. Ref. Part Name Remarks Part Name Remarks...
  • Page 218 Bracket P/L Fig. 20 Bracket, PTT & Gas Assistant 43-6 43-7 43-5 43-2 43-4 43-3 11-1 24 N·m (17 lb·ft) [2.4 kgf·m] 11-2 43-7 11 N·m (8 lb·ft) [1.1 kgf·m] Trim Meter 43-1 43-2 Trim Meter Kit (43-1∼43-7) Ref. Part Name Remarks Q'ty 43-1 Trim Meter...

  • Page 219: Power Trim & Tilt

    P/L Fig. 21 Power Trim & Tilt 35 N·m (18 lb·ft) [3.5 kgf·m] 155 N·m (112 lb·ft) [15.5 kgf·m] 5 N·m (4 lb·ft) [0.5 kgf·m] 1.5 N·m (1.1 lb·ft) [0.15 kgf·m] 22-1 2.5 N·m (1.8 lb·ft) [0.25 kgf·m] Chamfer 6 N·m (5 lb·ft) [0.6 kgf·m] 30-1 5.5 N·m (4 lb·ft) [0.55 kgf·m] 2 N·m (1.5 lb·ft) [0.2 kgf·m]...

  • Page 220: Tiller Handle

    Bracket P/L Fig. 12 Tiller Handle 6 N·m (4 lb·ft) [0.6 kgf·m] 41 N·m (30 lb·ft) [4.1 kgf·m] 1373B 1373B 1373B 1373B 1373B 16 19 1373B 1373B 1373B a Adjust Ref. Ref. Part Name Remarks Part Name Remarks Q'ty Q'ty 25 Washer Tiller Handle Tiller Handle Bushing...

  • Page 221: Bottom Cowl

    P/L Fig. 22 Bottom Cowl 6 N·m (4 lb·ft) [0.6 kgf·m] Ref. Ref. Part Name Remarks Part Name Remarks Q'ty Q'ty Bottom Cowl 1 Motor Cover (Lower) "Refer to 7-8 for PTT model." 25 Throttle Cable Grommet Cable Cover 26 Shift Decal (F, N, R) Bolt 27 Storage Decal Bolt...

  • Page 222: Shift

    Bracket P/L Fig. 16 Shift 6 N·m (4 lb·ft) [0.6 kgf·m] GEAR GEAR GEAR GEAR GEAR GEAR Ref. Part Name Remarks Q'ty Clutch Cam Cum Rod "S" Cam Rod "L" Cam Rod "UL" Spring Pin, 3-12 Cam Rod Bushing O Ring, 2.4-5.8 Do not reuse.
  • Page 223 P/L Fig. 17 Shift Throttle cam Shift cable Throttle cable 32-3 32-5 32-4 32-1 32-4 32-4 41 N·m (30 lb·ft) [4.1 kgf·m] Bottom cowl 32-3 32-2 1373B 1373B 1373B 36-4 1373B 36-2 36-3 36-5 36-6 1373B 36-1 1373B 1373B 1373B Selector "12P"...

  • Page 224: Inspection Items

    Bracket 4. Inspection Items 1) Inspection of Throttle Cable Check operation of throttle cable. Check throttle cable inner wire and outer wire for bend and damage. Replace if necessary. 2) Installation of Tiller Handle 1 as shown. Attach cables to throttle shaft Install throttle shaft 1 with cable to tiller handle.

  • Page 225: Adjustment Of Co-Pilot Plate

    Install cable b of which inner wire is stretched when acceleration grip is set to full close position. Then, install another cable a (of which inner wire is stretched when acceleration grip is set to full open position.) Adjust position of lock nuts 6 of throttle cable so that throttle grip can reach full open and full close positions.

  • Page 226: Removing Drive Shaft Housing

    Bracket 4) Removing Drive Shaft Housing Place draining container below drain hole, and remove drain bolt to drain gear oil. "Refer to Chapter 3." Remove bolt 1 and remove mount cover 2. 1342 1342 1342 Remove lower mount nuts 3 and bolts 4. Turn down lock plate tab 8, remove upper mount nut 5, and then, remove drive shaft housing ass'y 7.

  • Page 227: Pulling Out Upper Mount

    5) Pulling Out Upper Mount Pull out upper mount by using mount puller kit. 346-72761-0 345-72762-0 If it is seized, pull out only inner tube forcibly, 345-72763-0 and then, split outer tube by using chisel to remove it. Mount Puller Kit : 940191-1000 P/N.

  • Page 228: Inspection Of Oil Strainer

    Bracket 7) Inspection of Oil Strainer Check filter for dirt and sediment. Clean, or replace if necessary. 8) Assembly of Drive Shaft Housing Install water pipe 1 into drive shaft housing 2. Install oil strainer 3 on the engine base 5, and secure it with ties.

  • Page 229: Installation Of Drive Shaft Housing Ass'y

    Put upper mount q, washer, rubber and bolt w into engine base 5 hole, attach mount retainer e, and tighten bolt r with specified torque. Mount Retainer Bolt r : 6 N·m ( 4 lb·ft ) [ 0.6 kgf·m] 1342 1342 1342 9) Installation of Drive Shaft Housing Ass'y...

  • Page 230: Removing Steering Shaft

    Bracket 10) Removing Steering Shaft Remove drive shaft housing ass'y. For the procedure, refer to "Removing Drive Shaft Housing" in Chapter 7. Remove "C" ring 1. Remove mount bracket 2 by tapping it with plastic hammer. Pull out steering shaft from swivel bracket ass'y 3 to remove.

  • Page 231: Removing Clamp Bracket (Ptt Or Gas Assistant Model)

    Put grease through grease nipple 0 until grease leaks from bushing (upper) c. 12) Removing Clamp Bracket (PTT or Gas Assistant Model) Remove PTT unit or gas shock absorber. Refer to "Removing PTT Unit/Gas Shock Absorber" described later in this chapter. Remove nylon nut 1, and then, clamp bracket 2 and swivel bracket 3.

  • Page 232: Installation Of Clamp Bracket (Ptt Or Gas Assistant Model)

    Bracket 14) Installation of Clamp Bracket (PTT or Gas Assistant Model) Install swivel bracket shaft 2 to clamp bracket 1. Assemble swivel bracket 3 and clamp bracket 4, and tighten nylon nut 5 to specified torque. Nylon Nut 5 : 24N·m ( 17 lb·ft ) [ 2.4kgf·m ] Install PTT unit or shock absorber.

  • Page 233: Installation Of Clamp Bracket (Mechanical Tilt Model)

    15) Installation of Clamp Bracket (Mechanical Tilt Model) Install distance piece 2 and swivel bracket 3 to clamp bracket 1. Assemble swivel bracket 4 and clamp bracket 5, and tighten nylon nut 6 and nut 7 to specified torque. Nylon Nut 6 : 24 N·m ( 17 lb·ft ) [ 2.4 kgf·m ] Distance Piece Nut 7 : 6 N·m ( 4 lb·ft ) [ 0.6 kgf·m ]...

  • Page 234: Removing Ptt Unit/Gas Shock Absorber

    Bracket 16) Removing PTT Unit/Gas Shock Absorber Fully tilt up outboard motor and lock with tilt stopper 1. WARNING Be sure to lock outboard motor with tilt stopper after tilting up. Leaving outboard motor without locking may lead to accidental descent due to reduction of PTT hydraulic pressure.

  • Page 235: Removing Ptt Motor

    17) Removing PTT Motor Remove reservoir tank 2, PTT motor 3, O-ring 4 and 5, coupling 6 from PTT unit 1. CAUTION • When removing PTT motor (reservoir tank), fully extend tilt rod to prevent fluid from blasting out due to internal pressure. •...

  • Page 236: Removing Tilt Cylinder

    Bracket 20) Removing Tilt Cylinder Retract tilt rod. Use vise to fix PTT unit 1 that is protected at both sides with wood pieces or aluminum plates a. Secure joint 2 and loosen nut 3 by using wrench, and remove joint 2 and nut 3. Use 36mm deep socket to loosen tilt cylinder 4, stretch tilt rod and remove tilt cylinder 2.

  • Page 237: Inspection Of Valve

    22) Inspection of Valve Check tilt rod ass'y 1 check valve and valves for dirt and sediments. Clean if necessary. 23) Installation of PTT Pump and Motor Use vise to fix PTT unit 1 that is protected at both sides with wood pieces or aluminum plates.

  • Page 238: Assembly Of Tilt Cylinder

    Bracket Assemble new O-rings 9 and 0, coupling q, PTT motor ass'y 6 and reservoir tank 7, and tighten bolt 8 to specified torque. Reserve Tank Bolt : 5 N·m ( 4 lb·ft ) [ 0.5 kgf·m ] 24) Assembly of Tilt Cylinder Put new O-ring 2 on the tilt cylinder 1.
  • Page 239 Add PTT fluid to the first step of bottom of tilt cylinder installation hole. Recommended PTT Fluid : ATF DEXRON III Put ass'y of tilt cylinder 1, tilt rod 4, inner tube 8, free piston 6 and O-ring in the PTT unit 9. Install tilt cylinder 1 and tighten to specified torque.

  • Page 240: Air-Purging Ptt Unit (Separated From Outboard Motor)

    Bracket 25) Air-Purging PTT Unit (separated from outboard motor) Turn manual valve 1 counterclockwise fully. Manual Valve : 2 N·m ( 1.5 lb·ft ) [ 0.2 kgf·m ] Place PTT unit 2 vertically. Remove cap 3 and check fluid level in the reservoir tank. WARNING Check fluid level with tilt rod fully stretched.
  • Page 241 Reverse connection of PTT motor lead wires to battery terminals to fully stretch tilt rod. Battery Terminals Tilt Rod PTT Motor Lead Wires Blue (L) + : Positive Terminal Stretch Green (G) – : Negative Terminal • Repeat above steps several times to move up and down tilt rod (When reversing motor lead wire connection, keep the connection open for two or three seconds.).

  • Page 242: Installation Of Ptt Unit/Gas Shock Absorber

    Bracket 26) Installation of PTT Unit/Gas Shock Absorber Fully tilt up outboard motor and lock with tilt stopper 1. WARNING Be sure to lock outboard motor with tilt stopper after tilting up. Leaving outboard motor without locking may lead to accidental descent due to reduction of PTT hydraulic pressure.

  • Page 243: Air-Purging Ptt Unit (Separated From Outboard Motor)

    27) Air-Purging PTT Unit (installed on the outboard motor) Install outboard motor on the boat. Fully tilt up outboard motor and lock with tilt stopper. Remove cap 2 and check fluid level in the reservoir tank. Turn manual valve counterclockwise fully. Tilt up outboard motor fully with hands and let it tilt down gravitationally.

  • Page 244: Inspection Of Ptt Solenoid

    Bracket Add recommended PTT fluid to specified level if it is lacking. Recommended PTT Fluid : ATF DEXRON III Reservoir tank cap and tighten to specified torque. Reserve Tank Cap : 1.5 N·m ( 1.1 lb·ft ) [ 0.15 kgf·m ] Repeat steps from 5.

  • Page 245: Inspection Of Ptt Switch

    Check electrical conductivity between terminals 2 and 3. If ç DOWN non conductive, replace DOWN side PTT solenoid. 29) Inspection of PTT Switch Check electrical conductivity of PTT switch. Replace if other than specified conditions. Lead Wires Switch Position Sky Blue (Sb) Red (R) Pink (P) UP (Tilt Up)
  • Page 246 Bracket 7-36 25/30 2006...

  • Page 247: Electrical System

    Electrical System 1 Special Tools ………………………… 9) Inspection of Start Switch (Tiller Handle Model) … 8-17 2 Electrical Component Layout …… 10) Inspection of Stop Switch ………………… 8-18 5 Fuel Control System ………………… 8-19 Port Side View ………………………………… 8-3 1) Inspection of Injectors ……………………… 8-19 Bow Side View …………………………………...

  • Page 248: Special Tools

    Electrical System 1. Special Tools Vacuum/Pressure Gauge Spark Tester P/N. 3AC-99020-0 P/N. 3F3-72540-0 Inspecting pressure Inspecting sparks 25/30 2006...

  • Page 249: Electrical Component Layout

    2.Electrical Component Layout Port Side View 1 Fuel Feed Pump (FFP) : Interior of Vapor Separator 2 Starter Motor 3 Oil Pressure Switch 4 Water Temperature Sensor 5 Ignition Coil 25/30 2006...

  • Page 250: Bow Side View

    Electrical System Bow Side View 1 Starter Motor 2 Throttle Position Sensor 3 Fuel Feed Pump (FFP) : Interior of Vapor Separator 4 ISC (Idle Speed Control) Valve 5 Starter Solenoid 6 Warning Buzzer 25/30 2006...

  • Page 251: Starboard Side View

    Starboard Side View 1 Injector 2 ECU (Electronic Control Unit) 3 MAP (Manifold Pressure) Sensor 4 Rectifier 25/30 2006...

  • Page 252: Top View

    Electrical System Top View 4 #1 4 #2 1 Rectifier 2 Ignition Coil 3 PTT Solenoid 4 Pulser Coils 5 Starter Motor 6 Fuse (20A) 7 MAP (Manifold Pressure) Sensor 8 Alternator (Exciter Coil/Charge Coil/ECU Charge Coil) 9 Starter Solenoid 0 Water Temperature Sensor 25/30 2006...

  • Page 253: Tiller Handle Model

    Tiller Handle Model 1 Neutral Switch (Tiller Handle, Electric Start Model) 2 Warning Lamp (LED) 3 PTT Switch (PTT Model) 4 Stop Watch 5 Neutral Switch (Tiller Handle, Electric Start Model) 25/30 2006...

  • Page 254: Parts Layout

    Electrical System 3.Parts Layout P/L Fig. 8 150 N·m (108 lb·ft) [15.0 kgf·m] Magneto & ECU 6 N·m (4 lb·ft) [0.6 kgf·m] 1342 1342 Fig.2 6 N·m (4 lb·ft) [0.6 kgf·m] 13-1 16-1 1342 1342 22 20 27-1 1342 1342 1342 Ref.

  • Page 255: Electric Parts

    P/L Fig. 9 Electric Parts 22 Nám (16 lbáft) [2.2 kgfám] 31-1 13 Nám (9 lbáft) [1.3 kgfám] 53-1 8 Nám (6 lbáft) [0.8 kgfám] 1342 1342 1342 1741 1741 1741 13 Nám (9 lbáft) [1.3 kgfám] o Intake Manifold o Intake Silencer 1342 1342...

  • Page 256: Electric Parts

    Electrical System P/L Fig. 9 Electric Parts 22 Nám (16 lbáft) [2.2 kgfám] 31-1 13 Nám (9 lbáft) [1.3 kgfám] 53-1 8 Nám (6 lbáft) [0.8 kgfám] 1342 1342 1342 1741 1741 1741 13 Nám (9 lbáft) [1.3 kgfám] o Intake Manifold o Intake Silencer 1342 1342...

  • Page 257: Starter Motor

    Starter Motor P/L Fig. 10 1-12 1-10 1-13 1-11 Ref. Part Name Remarks Q'ty Starter Motor 1-1 Pinion Ass'y 1-2 Washer 1-3 Brush Holder 1-4 Screw 1-5 Bushing #1 1-6 Bushing #2 1-7 O-Ring 1-8 Washer 1-9 Spring Washer 1-10 Nut 1-11 Bolt 1-12 Washer 1-13 Spring Washer...

  • Page 258: Fuel Pump, Fuel Rail, Vapor Separator

    Electrical System Fuel Pump, Fuel Rail, Vapor Separator P/L Fig. 5 23-4 23-6 23-3 4st OIL 23-2 23-5 23-1 6 N·m (4 lb·ft) [0.6 kgf·m] 4st OIL 4st OIL 28-1 28-2 6 N·m (4 lb·ft) [0.6 kgf·m] Air Vent R/Mount To Fuel Pump Bottom Cowl Cylinder Block...
  • Page 259 P/L Fig. 5 Fuel Pump, Fuel Rail, Vapor Separator 23-4 23-6 23-3 4st OIL 23-2 23-5 23-1 6 N·m (4 lb·ft) [0.6 kgf·m] 4st OIL 4st OIL 28-1 28-2 6 N·m (4 lb·ft) [0.6 kgf·m] Air Vent R/Mount To Fuel Pump Bottom Cowl Cylinder Block To Fuel Rail...

  • Page 260: Ignition System, Ignition Control System

    Electrical System 4. Ignition System, Ignition Control System 1) Inspection of Ignition Sparks Disconnect plug caps from spark plugs. Connect plug cap to spark tester. Connect spark tester clip to spark plug tip electrode. Spark Tester : P/N. 3F3-72540-0 Spark Performance : 10 mm (0.4 in) or over Start engine and check sparks.

  • Page 261: Inspection Of Ignition Coils

    3) Inspection of Ignition Coils Remove ignition coil coupler. Measure ignition coil resistance. Replace if other than specified value. This test can be made without removing parts. Ignition Coil Resistance : Primary Coil : Between Black/White (B/W) - Black (B) 0.17 to 0.23 Ω...

  • Page 262: Inspection Of Pulser Coil

    Electrical System 5) Inspection of Pulser Coil Disconnect starboard side #1 pulser coil coupler 1 (2 pin). Measure #1 pulser coil resistance. Replace if other than specified value. Disconnect port side #2 pulser coil coupler 2 (1 pin), and check #2 pulser coil like #1 coil. This test can be made without removing parts.

  • Page 263: Inspection Of Water Temperature Sensor

    7) Inspection of Water Temperature Sensor Remove water temperature sensor to test it as a separate unit. Remove water temperature sensor from engine. Put water temperature sensor in the water, and warm up water slowly. Measure water temperature sensor resistance. Replace if the resistance is out of specified range.

  • Page 264: Inspection Of Stop Switch

    Electrical System 10) Inspection of Stop Switch Check electrical conductivity of stop switch. Replace if no conductivity. This test can be made without removing parts. Lead Wire Color Switch Position Brown (Br) Black (B) Remove lock. a Install lock. b Press switch.

  • Page 265: Fuel Control System

    5. Fuel Control System 1) Inspection of Injectors Measure injector resistance. • This test can be made without removing parts. • Injector operation test can be made by using "Function, or Running (Drop) Stop Test" of diagnosis system. Injector Resistance (Reference Value) : (at 20°C) 11.1 to 12.3 Ω...

  • Page 266: Inspection Of Mat (Manifold Temperature) Sensor

    Electrical System 3) Inspection of MAT (Manifold Temperature) Sensor Measure ambient temperature. Connect computer to outboard motor, and use diagnosis system to display "Air Temperature (Intake Air Temperature)". Replace MAT sensor if difference between ambient temperature and "Air Temperature (Intake Air Temperature)" is over ±...

  • Page 267: Starting System

    6.Starting System 1) Inspection of Fuse Check electrical conductivity of fuse. Replace if no conductivity. Flat or small sized plate fuse (20A) is adopted. 2) Inspection of Starter Solenoid Connect tester lead wires to both terminal of starter solenoid. Connector green (G) lead wire to battery positive terminal. Connector black (B) lead wire to battery negative terminal.

  • Page 268: Inspection Of Starter Motor Pinion

    Electrical System 4) Inspection of Starter Motor Pinion Check pinion teeth for crack and wear. Replace if necessary. Fix clutch 2, and turn only pinion 1 to check that it can be rotated smoothly in one direction. Replace if necessary. Turn pinion 1 counterclockwise to check that it can be rotated smoothly.

  • Page 269: Inspection Of Brushes

    6) Inspection of Brushes Measure brush length. Replace brush holder ass'y if brush length is less than specified value. Brush Length a : Standard Value 12.5 mm ( 0.492 in ) Wear Limit a : 9.5 mm ( 0.374 in ) Check conductivity of brush holder ass'y.

  • Page 270: Battery Charging System

    Electrical System 7.Battery Charging System 1) Inspection of Alternator Disconnect alternator coupler (3 pin). Measure alternator resistance. Replace if other than specified value. This test can be made without removing parts. Alternator (Charge Coil) Resistance : Reference Value (at 20°C) Between Yellow (Y) and Yellow (Y) (three types) 0.29 to 0.43 Ω...

  • Page 271: Ecu Coupler

    8.ECU Coupler • Check wire harness for disconnection of lead wire and defective connection. • Terminals are arranged and numbered as shown. • The following table names of terminals, their numbers and lead wire colors. Name Terminal Leas Wire (Color) Power Supply (INJ/FFP/ISC/Lamp) Blue Exciter Coils...
  • Page 272 Electrical System 8-26 25/30 2006...

  • Page 273: Troubleshooting O K

    Troubleshooting 1 Troubleshooting List 1) Software Install ………………………… 9-20 ………………… 9-2 2 Power Unit 2) If putting CD into CD drive will not cause ………………………………… 9-3 installation software to start. …………… 9-21 State 1 : Engine will not start or is a little hard to start. … 9-3 3) Diagnosis File Information ……………...

  • Page 274: Troubleshooting List

    Troubleshooting 1.Troubleshooting List * Low speed ESG operates. Probable Cause Fuel level is low in the tank. Fuel system connection is incomplete. Fuel system sucks air. Fuel pipe is twisted. Cap vent is closed. Fuel filter, fuel pump or injector is clogged. Low quality gasoline is used.

  • Page 275: Power Unit

    Before working on the engine, check that full, rigging and engine installation are normal, and then battery is fully charged. For mechanical troubleshooting, refer to relevant troubleshooting section in this chapter. For checking and servicing outboard motor, refer to service procedures described in this manual to perform the works safely.
  • Page 276 Troubleshooting Check electrical conductivity of neutral switch. Conductive? Replace neutral switch. Check start switch or main switch. Replace start switch or Normal? main switch key. Check electrical conductivity of wire harness. Repair or replace wire Conductive? harness. Disassemble starter motor to check.

  • Page 277: Ignition System

    Ignition System Check spark plugs. Clean and adjust Normal? spark plug, or replace. WARNING • When testing, put electrode cap assuredly to prevent Use spark tester to check direct contact with spark tester wiring and leak of ignition sparks. electrical current. •...
  • Page 278 Troubleshooting Replace ignition coil. Normal? Check alternator (exciter coil) resistance. Normal? Replace alternator. Check ECU. 25/30 2006...

  • Page 279: Fuel System

    Fuel System Check operation of fuel feed pump (FFP). Check electrical conductivity Operating noise of wire harness and fuse. heard? Repair or replace Conductive? defective parts. Check output from ECU to fuel feed pump (FFP). Check or replace ECU Output signal or alternator (ECU charge) exists? coil.
  • Page 280 Troubleshooting Replace fuel rail. Normal? Check fuel filter for clogging and dirt, and piping for leak. Repair and clean or Normal? replace defective parts. Check fuel pump. Replace fuel pump. Normal? Check vapor separator needle valve for bend and wear. Normal? Replace needle valve.

  • Page 281: Engine Revolution Speed Fall Off.engine Stalls

    State 2 Full throttle engine revolution speed is low. Engine revolution speed fall off. Engine stalls. (Defective acceleration or deceleration) Check battery cables for defective contact, and ground lead wire securing bolt for looseness or disconnection. Repair or replace Normal? defective parts.

  • Page 282: Ignition System

    Troubleshooting Ignition System Check spark plugs. Clean and adjust Normal? spark plug, or replace. WARNING • When testing, put electrode cap assuredly to prevent Use spark tester to check direct contact with spark tester wiring and leak of ignition sparks. electrical current.

  • Page 283: Fuel System

    Fuel System Check fuel filter for clogging and dirt, and piping for leak. Repair or replace Normal? defective parts. Measure fuel pressure. Out of specified Check injector clogging and range? resistance. Replace injector. Normal? Check ignition system, Check fuel regulator of vapor separator.

  • Page 284: Lubrication System

    Troubleshooting Check needle valve of vapor separator. Replace needle valve. Normal? Check ignition system, lubrication system and/or cooling system. Lubrication System Check engine oil level. Add engine oil to Within specified specified level. range? Check oil pressure switch. Normal? Replace oil pressure switch. Measure hydraulic pressure.

  • Page 285: Cooling System

    Cooling System Check cooling water passage for clogging or leak. Clean or replace cooling Normal? water passage. Check thermostat. Normal? Replace thermostat. Measure water temperature sensor resistance. Replace water Normal? temperature sensor. Check water pump. Replace water pump. Normal? Check ignition system, fuel system and/or lubrication system.

  • Page 286: In Low Speed Range

    Troubleshooting State 3 Engine rotation is unstable or hunting occurs in low speed range. Check throttle position sensor and ISC valve connectors for connections and resistances. Repair or replace Normal? defective parts. Check throttle link and throttle valve for play and wear.

  • Page 287: Ignition System

    Ignition System Check spark plugs. Clean and adjust Normal? spark plug, or replace. WARNING Use spark tester to check • When testing, put electrode cap assuredly to prevent ignition sparks. direct contact with spark tester wiring and leak of electrical current. •...

  • Page 288: Fuel System

    Troubleshooting Fuel System Check fuel pump. Replace fuel pump. Normal? Check vapor separator needle valve for bend and wear. Normal? Replace needle valve. Check injector clogging and resistance. Normal? Replace injector. Check ignition system. 9-16 25/30 2006...

  • Page 289: Ptt Unit

    3.PTT Unit State 1 PTT will not operate. Check operation of PTT motor. Operating Check battery and fuse. noise heard? Repair or replace Normal? defective parts. Check electrical conductivity of PTT switch. Replace PTT switch. Conductive? Check electrical conductivity of PTT solenoid. Conductive? Replace PTT solenoid.

  • Page 290: State 2 Ptt Is Not Capable Of Sustaining Outboard Motor

    Troubleshooting Check PTT fluid level. Within specified Add PTT fluid to specified range? level. Disassemble PTT unit to check. State 2 PTT is not capable of sustaining outboard motor. Check that manual valve is closed. Close manual valve. Closed? Check PTT fluid level. Within specified Add PTT fluid to specified range?

  • Page 291: 3Ac Diagnosis

    4.3AC Diagnosis 1.Set Up Read this manual thoroughly, connect diagnosis cable to computer, and then, perform software operations. • Check that computer is normal. • Fully charge battery. • Clean battery terminal to remove dirt and corrosion, and connect battery cables securely. •...

  • Page 292: Software Install

    Troubleshooting 1) Software Install The software is installed automatically once CD is set in the CD drive of computer. After the software is installed, select "3AC DIAGNOSTICS" from "PROGRAM" to start the program. After computer is restarted, the program is started simply by double-clicking the short-cut icon on the desktop.

  • Page 293: If Putting Cd Into Cd Drive Will Not Cause Installation Software To Start

    2) If putting CD into CD drive will not cause installation software to start. Double-click "install.exe" contained in the CD. Installation software will start. 3) Diagnosis File Information File Names Contents 3AC_DIAG.exe File that comprises 3AC DIAGNOSIS. SYSTEM.INI AUTORUN.ICO File for installing files of 3AC AUTORUN.INF DIAGNOSIS into computer.

  • Page 294: Hardware Connection

    Troubleshooting 2.Hardware Connection 1) Preparation Diagnosis Harness ON/OFF switch Battery (12V) for function test Computer and running (drop) test Connected to battery. (Starting battery Diagnosis can be used.) Harness Connected to ECU Connected to computer (Engine) *RS232C Port (9 Pins) If your computer is not provided with RS232C Port (9 Pins), use USB conversion cable as shown.

  • Page 295: Position Of On/Off Switch For Function Test And Running (Drop) Test

    3.Position of ON/OFF switch for function test and running (drop) test In principle, use 3AC DIAGNOSIS with the switch set to OFF. Use ON position only for function test and running (drop) test. OFF : Test history is updated. Use this position for other than function test and running (drop) test.

  • Page 296: Operating Procedure

    Troubleshooting 4.Operating Procedure Operating procedure is possible to be renewed. Using the newest version is always recommended. 1) Start Up Double-click "3AC_DIAGNOSTICS" in "PROGRAM" or its short-cut icon. Menu screen appears. 2) Menu Selection Use " " or " " key on the keyboard or press the number to move cursor to menu item to be executed, and press "Enter"...

  • Page 297: Setting Communication (Com) Port

    4) Setting Communication (COM) Port RS232C port. "Com port No = " Current COM port number appears. "New Com Port No = " New COM port number can be input. Input COM port number of your computer. Press "Enter" key to return to "Menu" screen. •...

  • Page 298: Monitoring Ecu Data

    Troubleshooting 5) Monitoring ECU data Current states of engine can be seen on the screen. Press "F1" key to return to "Menu" screen. 9-26 25/30 2006...

  • Page 299: Monitoring History And Failure Code Retrieval

    6) Monitoring History and failure code retrieval Malfunction history of engine can be seen on the screen. Press "F1" key to return to "Menu" screen. 25/30 2006 9-27...

  • Page 300: Function Test

    Troubleshooting 7) Function Test Set switch of diagnosis harness to "ON" when performing function test. Malfunction of injectors or their operating state can be checked. Enter the number of item to be checked. "1" : Operation (on/off) of #1 injector "2"...

  • Page 301: Running Test (Drop Test)

    8) Running Test ( Drop Test ) Set switch of diagnosis harness to "ON" when performing running (drop) test. This test stops operation injector or ignition coil temporarily during engine operation for checking operating state according to reduction or operating noise level and engine speed.

  • Page 302: Air Purging From High Pressure Fuel Circuit

    Troubleshooting 9) Air Purging from high pressure fuel circuit Squeeze fuel primer bulb repeatedly until it becomes hard to feed fuel to vapor separator. * Press "1" key to operate fuel feed pump (FFP) for two seconds to feed fuel to all injectors. * Then, pulling recoil starter opens all injectors to purge air from high pressure fuel circuit.

  • Page 303: Exit Diagnostic

    10) Explanation of Error code Description of error code appears on the screen. Example : Error code : 1 Communication Error Communication with ECU is not ready. Check following items. * Connection between computer and ECU * Connection with battery * Setting of computer COM port number.
  • Page 304 Troubleshooting 9-32 25/30 2006...

  • Page 305: Accessories

    Accessories r/min r/min 1 Remote Control Components 3 Operation ……… 10-2 ……………………………… 10-7 1) Installation of Remote Control Cable (Engine Side) 1) Warning Indication ……………………… 10-7 Remote Control Model …………………… 10-2 2 Installation of Meters and Battery … 10-5 1) Installation of Meters ……………………… 10-5 2) Installation of Battery ………………………...

  • Page 306: Remote Control Components

    Accessories r/min 1.Remote Control Components 1) Installation of Remote Control Cable (Engine Side) Remote Control Model Turn hook lever on the bottom cowl downward and remove top cowl. Remove cable joint snap pins 3 and washers from throttle side 1 and shift side 2, and then, remove two cable joints. Screw cable joint on the tip of remote control cable by approximately 10mm.
  • Page 307 Set remote control lever 4 to neutral (N) c, and check that neutral throttling lever 5 is at full close position b. Set shift arm 6 to forward (F), neutral (N), reverse (R) and then to neutral (N) positions. Set throttle drum 7 to full close position. Check that throttle valve contacts with full close stopper.
  • Page 308 Accessories r/min Lock joint with nut 0, put it on the pin, and secure with washer and snap pin q. Check that shifting control lever 4 forward (F) by approximately 32 degrees (d) , where it is stopped once, makes the gear engage, and fully shifting the lever makes throttle valve fully open, and then, check that shifting the lever reverse (R) by approximately 32 degrees (e), where it is stopped once, makes the gear engage, and fully shifting...

  • Page 309: Installation Of Meters And Battery

    2.Installation of Meters and Battery 1) Installation of Meters When installing meters, select a place on the dash board 1 where operator can watch them easily and they are not exposed to water spray. The meters can be installed on the dash board 1 of 2 to 11mm thick.

  • Page 310: Wiring Diagram Of Remote And Control Meters

    Accessories r/min 3) Wiring Diagram of Remote and Control Meters Color Code ：Black L ：Blue Lg ：Light Green O ：Orange P ：Pink R ：Red Sb ：Sky Blue W ：White Y ：Yellow G ：Green Y/R ：Yellow/Red/ G/R ：Green/Red Note : Leads marked with are connected with meter lamp switch (option) is...

  • Page 311: Operation

    3.Operation 1) Warning Indication When an abnormality occurs on the engine, warning buzzer sounds and warning lamp is lit or blinks. Take actions described below if abnormal state has occurred. When engine started, warning lamp is lit for 5 seconds and warning buzzer operates for two seconds (generating intermittent sound) indicating that operation warning system is operating normally.
  • Page 312 Accessories r/min Oil Pressure Warning When Oil pressure is reduced below setting value during operation, warning buzzer operates (generating continuous sound), warning lamp is lit, and at the same time, low speed ESG operates to reduce the speed to 2,800r/min or less. •...

  • Page 313: Wiring Chart

    Wiring Diagram 1 Wiring Chart 3 EF/EFG/EFT Model ……………………………… 11-2 ………………… 11-4 2 MF/MFG Model 4 EP/EPG/EPT Model …………………………… 11-3 ………………… 11-5...

  • Page 314: Wiring Diagram

    Wiring Diagram NO. Name Remarks Lead Wire Color Flywheel Magneto – – – – Exciter Coils Located in the alternator White/Blue White/Black White/Red – – ECU Charge Coil Located in the alternator White White Charge Coil Located in the alternator Å| Yellow Yellow...
  • Page 315 FLYWHEEL CHARGE COIL ECU/CHARGE COIL WARNING LANP BOTTOM COWL 25/30 2006 11-3...
  • Page 316 FLYWHEEL CHARGE COIL START ASS’Y ECU/CHARGE COIL WARNING LANP BOTTOM COWL 25/30 2006 11-4...
  • Page 317 FLYWHEEL CHARGE COIL ECU/CHARGE COIL & WARNING LANP BOTTOM COWL 25/30 2006 11-5...
  • Page 319 OB No.003-21054-1 06-02 NB-2600 Printed in Japan...

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